System for producing wood-framed buildings having class-a fire-protection during construction, and certifying and documenting the same

ABSTRACT

A method of and system for producing wood-framed buildings having Class-A fire-protection and defense against total fire destruction during the construction phase, and certifying and documenting the same. The system includes a reservoir for containing a supply of clean fire inhibiting liquid chemical (CFIC) liquid for spray application over over the interior surfaces of raw and treated lumber and sheathing used in a completed section of a wood-framed assemblies in a wood-framed building during its construction phase; a liquid spray pumping subsystem operably connected to the reservoir tank containing the supply of CFIC liquid. A hand-held liquid spray gun, operably connected to the liquid spray pumping subsystem, is used to for spray CFIC liquid from the reservoir tank onto the exposed interior wood surfaces of lumber and sheathing used to construct each completed section of the wood-framed building, to form a CFIC coating on the treated interior wood surfaces providing Class-A fire-protection to the completed section of the wood-framed building.

RELATED CASES

The present Patent Application is a Continuation of application Ser. No.15/829,914 filed Dec. 2, 2017, commonly owned by M-Fire Suppression,Inc., and incorporated herein by reference as if fully set forth herein.

BACKGROUND OF INVENTION Field of Invention

The present invention is directed toward improvements in buildingconstruction, and more particularly, the construction of multi-storybuildings made from wood, lumber and wood-based products, offeringimproved defense against the ravaging and destructive forces of fire.

Brief Description of The State of Knowledge in The Art

Wood-framed construction offers a number of benefits formulti-residential and mixed-use projects. It allows developers to createhigh-density, high-quality housing that's also cost effective, with theadded advantages of a shorter construction schedule and lighter carbonfootprint. The detailing of mid-rise wood buildings plays a significantrole in the ability to manage investment costs per unit and best use thelot configuration. Implementing a well-considered structural designrequires understanding and coordination of several architectural designprinciples, such as fire/life safety, acoustics, building envelope andconstructability.

Today, multi-story raw light wood-framed buildings under constructionare burning down across the United States and Canada causing hundreds ofmillions of dollars worth of damage and disrupting the lives ofthousands of people.

For example, in January 2017, in Maplewood, N.J., a nearly completed,four-story 235-unit apartment complex caught fire. The massive six-alarmfire required 120 fire fighters from two dozen fire companies toextinguish the fire before it got to the completed section.

In March 2017, in downtown Raleigh, Carolina, a seven story apartmentbuilding under construction caught fire. The five alarm fire was thelargest fire the City has seen in 100 years and caused $12 milliondollars in damage. The fire also damaged 10 nearby buildings, five ofwhich were damaged severely.

In March 2017, in Overland Park, Kans., a four-story Apartment buildingunder construction caught fire from a welder's torch. This was a massiveeight-alarm fire which also caught 22 large homes in the neighborhood onfire.

In April 2017, in College Park, Md., a nearly completed, four storyapartment building caught fire. The five alarm fire caused $39 milliondamage. The fire forced the closure of the nearby University of Marylandand the evacuation of a Senior Center and 200 firefighters were neededto contain the massive blaze.

On Dec. 8, 2014, a fire destroyed the seven-story Da Vinci Apartmentcomplex that was under construction at the time. The massive fire alsodamaged nearby buildings and Interstate 110. The fire was set byarsonist, Dawud Abdulwali, who was convicted and sentenced to 15 yearsin prison. Prosecutors alleged he set the fire in anger over fatalpolice shootings of African Americans in Ferguson, Mo., and othercities. The spread of radiant heat from the fire was the primary causeof damages to nearby buildings, activating fire sprinklers and causingwater damage. Great expenses were incurred by the City of Angeles due tofirefighting activities necessary to put out the fire and prevent itfrom spreading to other properties.

These are just a few examples of where wood-framed buildings arecatching on fire these days during construction, prior to sprinklers anddrywall being installed in place and made active to protect the wood.Construction fires most frequently occur in buildings constructedwithout fire treated lumber, and the buildings which use fire treatedlumber, only use it on the exterior walls, where such fire treatedlumber offers little or no help on burning buildings.

In general, the definition of light wood frame construction is where theroof and floor trusses are made out of 2×4 or 2×6 lumber and OrientedStrand Board (OSB) sheathing as shown in FIGS. 5A and 5B, and engineeredwood products or components (EWPs) such as I-joists as shown in FIGS. 6Aand 6B. Building with these components requires builders to make bestefforts to protect such components and assemblies made therefrom duringconstruction, using full time security guards, and in some cases,temporary sprinkler systems. Today's OSB sheathing and EWPs ignite veryfast and advance and spread beyond what fireman can contain by the timethey arrive on site at the fire.

While environmentally-safe fire inhibitors are available to coat suchOSB sheathing and EWPs, to contain the fire before it progresses to thecritical stage, allowing fireman to put out the ignition source.However, as in many industries, the problem is that building anddeveloping is a very competitive industry and developers are reluctantto add to their costs unless they are required to make their buildingssafe to build and safer to live in. A similar example is the automobileindustry where seat belts were non-existent or optional until Congressmandated minimum federal standards in 1963, and in 1966 finally passedthe National Traffic and Motor Vehicle Safety Act. This federal lawformally established Federal Motor Vehicle Safety Standards (“FMVSS”)providing minimum legally acceptable requirements for the manufacturingof vehicle components, including seat belts and seat belt buckles. Thislegislation also made the installation of seat belts mandatory by U.S.automakers.

Wood framed buildings are most vulnerable to fire during the framingstage of building construction—before sprinklers, firewalls or gypsumboard linings are installed to protect the structure. There are manyactivities during construction that can cause a fire to start.Construction activities are a major cause of fire, but so is arson whichseems to be on the rise across the USA.

There is a commonality in all the recent catastrophic fires in mid-risemulti-story apartment buildings 1A, 1B and 2, as schematicallyillustrated in FIGS. 1A, 1B and 2. All of these recent catastrophicfires used lighter roof and floor trusses or I joists and sheathed withOSB, instead of plywood, and when they caught fire, the rapid advance ofthe fire was beyond what could be controlled with water as a fireextinguishing agent. It will be helpful at this stage to review buildingcodes allowed in such wood-framed multi-story apartment buildings 2, asillustrated in FIG. 3.

The International Building Code allows for five types of construction:

Type I & II: Where all building elements are made of non-combustiblematerials.

Type III: Where exterior walls are made of non-combustible materials,and the interior building elements are always raw lumber 3 as shown inFIG. 4, and permitted by the code.

Type IV: H.T. (Heavy Timber) Where exterior walls are made ofnon-combustible materials, and the interior building elements are madeof solid or laminated wood without concealed spaces.

Type V: Structural elements, exterior and interior walls are made of anyraw materials permitted by the code.

A. Fire-resistance rated construction.

B. Non-fire-resistance rated construction.

In the view the current International Building Code, clearly there is amajor design flaw in the structural components and sheathing innovationsintroduced in the early 1980's, and now used to build high-densitystructures that are burning down in record numbers.

Since the boom after World War 2, the U.S. Government began limiting thecutting of old growth forests as they were being over harvested. Sincethen, US reforestration programs have been working very well, and the UShas reforested millions of acres. Big saw mills and lumber producerswere able to foresee having trouble keeping up with the forecastedhousing starts, and that there was a big difference in reforested lumberin bending values and the ⅓ less veneers the juvenile lumber produces.This fact created opportunity for a number of much-needed woodconstruction products, namely: light-weight floors trusses as shown inFIGS. 7A, 7B and 7C and roof trusses in FIG. 9 constructed typicallyusing untreated lumber shown in FIG. 4 and metal (truss) connectorplates shown in FIGS. 7B, 8A and 8B; OSB sheathing shown in FIGS. 5A and5B; I-Joists shown in FIGS. 6A and 6B; and other engineered woodproducts (EWPs).

While all of these wood products are great innovations and are needed tosupport housing starts, the big problem is that such wood products haveserious design flaws when it comes to fire-protection, because (i) theyignite faster than old growth lumber, and (ii) the advance of fire is sorapid with these wood product that they have changed how our firemenhandle fire rescue missions because roofs and floors collapse so fastbuilding such fires fueled by these wood products.

Raw untreated oriented strand board (OSB) 4 as illustrated in FIG. 5Aand described in U.S. Pat. No. 6,098,679 has had an enormous impact onthe building industry in many ways. OSB is a wood-based constructionsheathing product comprised of wood strands that are sliced from logs,dried, mixed with relatively small quantities of wax and resin,typically less than 3.5% by total weight, formed in mats with theorientation of the wood strands controlled in the length and widthdirections. The mats of wood strands are then pressed together underheat and pressure, and thermosetting polymeric bonds are created,binding together the adhesive and wood strands to achieve rigid,structural grade panels. It is during this pressing and consolidationprocess that the wood is compressed by a factor of 1.35 to 1.70 timesits original density. The final panels are dry when made. When used inconstruction, they will often take on moisture from ambient air and/orprecipitation, thus exerting swelling forces on the panel as it attemptsto regain its natural form and density.

Research confirms that lightweight wood-framed buildings sheathed withOSB material ignite easier and burn faster, and lightweight trusses andI-joists collapse much faster than like building assemblies onceconstructed from old growth solid lumber. The fire performancecharacteristic of conventional building components as shown in the testdata tables from a UL Report dated 8 Sep. 2008, set forth in FIGS. 10A,10B and 11. The introduction of engineered wood products (EWPs) such asI-joists 6A, 6B, 6C and 6D and 7 shown in FIGS. 6A and 6B, metal plateconnected roof and floor trusses 8, 11, 13 shown in FIGS. 7A, 7B, 7C and9, and OSB sheathing 4 shown in FIG. 5A, are to blame for thesebuildings burning during construction. These fires are attacking thesustainable aspect of our renewable timber resources used for housing.

Since the 1980's, engineered wood products (EWPs) such as floor trussesand I-joists have been increasing in market share over solid timberjoists in floors and roofs. These innovations were needed becauseopen-concept planned houses required building products that could spanlonger. In addition, it was found that new-growth timber was not asstrong as the old growth timber, especially in terms of bendingstrength. The need was great and all these new innovations satisfied theneed and took market share. However, the fire problem increased, and inChicago, firemen lost their lives in floor collapses.

The major design flaw in engineered wood products only started to bechallenged in the mid-to-late 1990's, prompting, the two largestproducers of OSB and I-joists, such as Louisiana & Pacific (LP), tointroduce fire-rated products, such as its fire-rated FlameBlock® OSB 5shown in FIG. 5B and FlameBlock® I-Joist 7 shown in FIG. 6B, to providefire-rated OSB sheathing and fire-rated I-joists that help combat firewhich challenges safety. LP's FlameBlock® wood products use fireretardant coatings based on magnesium compounds which were originallydisclosed by Harold Ellis in U.S. Pat. Nos. 4,572,862 and 5,130,184,incorporated herein by reference. A review of such product innovationsshould help illustrate both the advantages and drawbacks which fireretardant treated product provide.

Numerous manufacturers offer fire-retardant lumber products based onintumescent coatings, many similar to that used in LP's FlameBlock® woodproducts. One example is PKShield™ intumescent-coated wood products byPinkwood, Ltd., of Calgary, AB Canada.http://www.pinkwood.ca/pkshield-us/

The advantages of PHShield™ wood is to delay the ignition of fire, andreduce the spread of fire. When wood coated with PKShield™ intumescentcoating is exposed to flame, the coating begins to expand and forms aprotective barrier between the ignition source and the wood. Thisbarrier delays the time it takes for wood to actually ignite and sustaina flame compared to uncoated lumber. Should a fire occur, wood coatedwith PKShield™ intumescent coating slows the spread of flame to offeradditional time for occupants to escape the building and firemen tocombat the fire.

As shown in FIG. 6A, the web portion of a conventional untreated I-joist6A, 6B, 6C and 6D is made from ⅜″ thick (OSB) sheathing. In a fire, theOSB web portion will burn through in less than 6 minutes, which isapproximately how long it takes for a fire department to arrive on thescene of a fire not be set up to defend. Once the web is burned away, anOSB I-joist has completely lost its load carrying capability. While theI-joist flange appears intact (as this part takes longer to burnthrough), the web portion is burned away, and from above the floor wouldappear to be intact. Firefighters arriving on scene would not expectthat the floor doesn't have any structural strength as they are familiarwith solid sawn 2×10 floor joists which take approximately 14 minutes toburn to failure. If a firefighter were to stand on the I-joist floorafter six minutes or so burning, they are in danger of falling throughthe floor and being burned to death in the basement of the building. Asshown in FIG. 6B, the white-colored Pyrotite® coated web portion of theLP's FlameBlock® I-Joist 7 offers an improved fire rating over theuntreated conventional I-joist design 6A-6D shown in FIG. 6A.

As shown in FIGS. 7A, 7B and 9, most conventional top chord bearingfloor and roof trusses 8 and 13 are built with 2×4 and 2×6 lumbersections which are connected together using punched metal connectorplates 10, often having integrated teeth or nail spikes 10B projectingfrom its mounting plate 10A, as shown in FIG. 8A and 8B. Typically, theteeth of the metal connector plates 10 are pressed into the lumbersections of the truss structure during manufacturing, so as to secureconnect them together to form a very strong and light-weight trussstructure. It is important to note here that these trusses were requiredto replace the depleting volume of old growth lumber of suitable lengththat could meet the spans of modern wood-framed buildings underconstruction. The design flaw with conventional wood-framed trussstructures and assemblies 8 and 13 is that, in a fire, the short teeth10A projecting from the metal truss plates 10 release from the lumbersections 9A and 9B as the lumber burns, as illustrated in FIG. 15. Thisfailure results in the quick collapse of floor and roof structuresconstructed using such conventional building construction components.

During the ten years that these innovations have been taking hold of thebuilding industry, fireman have been losing their lives in wood-framedbuilding fires because they were not accustomed to the floors and theroofs collapsing so fast due to the fire burning characteristics ofmodern engineered wood products (EWPs) used to construct the floor andtruss structures used in these buildings. Today, fireman are beingbetter trained to assess such building structures before they run into aburning building on fire, but still are exposed to such risks posed bythese conventional building technologies.

Perhaps one of the biggest problems in today's wood-framed buildings isrelated to the fact that OSB material fuels fire consumption inunprecented ways. As old growth timber was becoming more difficult tocut due to environmental issues and concerns, the price of old growthlogs went up, causing the veneers used to make plywood to become moreexpensive than the small thin trees chopped down to make OSB.Consequently, due to its lower price advantage, OSB sheathing took overthe building industry in production housing, despite its hidden firedesign flaw.

The hidden, inconvenient truth behind wood-framed structures is that oldhomes built with solid lumber floor joists and roof rafters, sheathedwith either 1×6 or plywood, is less vulnerable than today's light-weightwood products. This is a major issue for the fire fighting community andthey have not been silent about it. The National Fire-protection Agencypublished an article in July 2009 issue of NFPA Journal, on the Dangersof Lightweight Construction, discussing the results of two studies anddetailing the relationship between fire and engineered wood constructionassemblies—notably, that they burn quicker and fail faster than theirsolid dimensional lumber counterparts.

In September of 2008, the Chicago Fire Department (CFD) championed astudy by Underwriters Laboratories, Inc. (UL) entitled “StructuralStability of Engineered Lumber in Fire Conditions” (Project Number:07CA42520). Summaries of Test Samples and Results (ASTM E119) are setforth in FIGS. 10A and 10B, summarizing the fire testing of floor androof systems that were unprotected and protected with a layer of ½″gypsum board. The results confirmed what the fire fighters werereporting in the field, that I-joists and floor trusses burned fasterthan solid 2×10's.

In December of 2008, National Research Council of Canada (NRC) conductedsimilar testing and published a report with similar results to the ULreport. An excerpt from the NRC Report reads as follows: “It must bepointed out that the times to reach structural failure for the woodI-joist, steel C-joist, metal plate and metal web wood truss assemblieswere 35-60% shorter than that for the solid wood joist assemblyresulting in smaller time difference between the onset of untenableconditions and structural failure of these engineered floor assemblies.”Table 8 from the December 2008 NRC Report is set forth in FIG. 11 forconvenience, summarizing the time of failure (t_(f)) of variousunprotected floor assemblies tested.

The above identified studies by UL and the NRC, and numerous complaintsfrom fire fighters, have resulted in changes to the InternationalResidential Code in 2012, under section R501.3. While there are manyspecial interest groups urging lawmakers to introduce legislation tomandate the use of concrete and steel for mid-rise construction, suchmeasures would significantly (i) increase building cost, (ii) lengthenconstruction schedules, and (iii) decrease affordability at a time whenthe need to increase affordability is very great.

In general, economic cost has stalled the advance of defending more ofthe lumber in buildings. Some wood frame buildings call for the use ofFire Retardant Treated Lumber (FRT) which is covered under Clause 2303.2of the 2015 International Building Code as follows: “Fire RetardantTreated lumber is any wood product which, when impregnated withchemicals by a process or other means during manufacture, shall have,when tested in accordance with ASTM E-84 or UL 723, a listed flamespread index of 25 or less and show no evidence of significantprogressive combustion when the test is continued for an additional20-minute period. Additionally, the flame front shall not progress morethan 10½ feet (3200 mm) beyond the centerline of the burners at any timeduring the test.”

Under National Fire Protection Association (NFPA) and InternationalBuilding Code (IBC) specifications, tested fire-treated wood productsshall receive a Class-A fire-protection rating provided that FlameSpread index measures in the range of 0 through 25, and Smoke Developedindex measure in the range of less than or equal to 450. Testedfire-treated wood products shall receive a Class-B fire-protectionprovided that Flame Spread index measures in the range of 26 through 75,and Smoke Developed index measure in the range of less than or equal to450. Also, tested fire-treated wood products shall receive a Class-Cfire-protection provided that Flame Spread index measure in the range of76 through 200, and Smoke Developed index also measure in the range ofless than or equal to 450.

A major problem associated with the use of pressure-treated fireretardant treated (FRT) lumber is that the use of FRT chemicals duringpressure-treatment lowers the PH of the wood, which results in acidhydrolysis, also known as acid catalyzed dehydration. Thispressure-based process of fire retardant treatment attacks the fiber ofthe wood, causing it to become brittle and lose its strength.Significant losses in the modulus of elasticity (MOE), a measure ofstiffness, the modulus of rupture (MOR), a measure of bending strength,and impact resistance, a measure of strength, can occur during thepressure-treatment process. These modes of failure include heavychecking parallel and perpendicular to the grain, splitting, and fullcross grain breaks. Eventually the degradation continues to the pointthat the wood becomes so weak and brittle that it actually snaps undernormal loading conditions. This process is insidious in that it isprogressive, and latent.

There are many products on the market that are acceptable alternativeproducts and can replace FRT lumber by means other than pressureimpregnating. Such products include commercially available fireretardant and fire inhibitor products that work very well at stalling afire's ignition, and are less than half the cost of trying to fire treat100% of lumber and sheathing with the old, traditionalpressure-impregnated fire retardants. These alternative fire inhibitingchemical products, even though not pressure-permeated or similarlyprocessed, still perform to the level required by the code and can beused interchangeably with the FRT lumber or by themselves.

Examples of prior art fire-treated wood produced usingnon-pressure-treated methods include ECO RED SHIELD FT™ fire treatedlumber by Eco Building Products, Inc. of San Diego, Calif. In 2014, ECORED SHIELD FT™ fire treated lumber was produced using Eco BuildingProduct's fire inhibitor formulated using a mixture of chemicalsincluding liquid polymer, PW40 biocide, disodium octaborate tetrahydrate(DOT) for termites, and Hartindo AF21 total fire inhibitor from HartindoChemicatama Industri of Jakarta, Indonesia. It was later discovered thatthese chemical components interacted chemically in an undesired manner,to significantly reduce the fire-inhibiting performance of Hartindo AF21fire inhibitor when used to treat to wood products.

Then, in 2016, Eco Building Product's changed its formula for ECO REDSHIELD FT™ fire treated lumber, and began using Eco Building Product'sproprietary Eco AFL™ fire inhibitors, specifically its FRC12™ fireretarding chemical formulation, and wood surface film concentrateformulation (WSFC).

Eco Building Product's wood surface film concentrate formulations, andmethods of preserving wood and inhibiting the emission of naturallyoccurring formaldehyde, are disclosed in pending U.S. patent applicationSer. No. 15/238,463 entitled “Formulation and Method for PreservingWood” filed on Nov. 4, 2016. Eco Building Product's fire retardingformulation and methods are disclosed in U.S. patent application Ser.No. 15/238,463 entitled “Fire Inhibitor Formulation” filed on Aug. 16,2016. Both of these US Patent Applications are incorporated herein byreference.

There is another factor at work influencing high-density builders todefend all wood used on new building construction, and that is whetheror not the builder has lost a building to fire. If so, then the primaryoption of such high-density builders is to demand their liabilityinsurance providers to either reduce or not increase their insurance ifthey defend 100% of the lumber on new wood-framed building construction.If high-density builders and insurance companies work together, thenthere is a high likelihood that building codes will begin to adopt thesenew less expensive ways of defending lumber from fire, to the benefit ofeveryone.

A major problem with the current building code, and the way large,lightweight, wood-framed, multi-story buildings are designed, is thattypically only the exterior walls require or specify the use of FRTlumber. This is illustrated in the wood bearing wall schedule andarchitectural plans set forth in FIGS. 11 and 12. As shown in FIG. 12,the architectural specification 14 provides a schedule whereload-bearing walls made from FRT lumber are required. As shown in thearchitectural specification 15 in FIG. 13, only the exterior walls 16are specified as FRT lumber. However, as experience has shown the worldover, a fire can easily start on the untreated wood in the interior of awood-framed building, and quickly spread to burn down the entirebuilding structure, as shown in FIGS. 14A and 14B. As illustrated in thevideo footage of the Houston Apartment Fire on Mar. 25, 2014, theexterior walls made from FRT lumber can do a good job resisting thefire, but can only do so up to a certain point, and when the interiorsupport is gone, the exterior FRT lumber walls fall as a unit, which isvery hazardous to fire fighters.

Other factors operate allowing the industry to continue buildinghigh-density buildings with raw untreated lumber. For example, manybuilding departments are relying on building permit revenue from suchhigh-density buildings, and they are reluctant to encourage builders tomove to other regions. Therefore, they allow them to rebuildhigh-density type construction, even after a fire in a building that wasbuilt with untreated lumber.

In effort to prevent total fire destruction of wood-framed buildings, itis helpful if not essential to understand the nature of the fire cyclebefore understanding how flame retardants, inhibitors and extinguisherswork to suppress and extinguish fires.

In FIG. 16, the fire cycle 17 is graphically illustrated as having thefollowing four essential components: (i) ignition source (e.g., heat,incandescent material, a small flame); (ii) fuel material (e.g., wood,wax, fuel, etc.); (iii) oxygen; and (iv) the free radicals (H+, OH—, O—)18 associated with the process of combustion.

In general, the ignition source can be any energy source (e.g. heat,incandescent material, a small flame, a spark, etc.). The function ofthe ignition source is to start the material to burn and decompose(pyrolysis), releasing flammable gases. If solid materials in theignition source do not break down into gases, they remain in a condensedphase. During this condensed phase, the material will slowly smolderand, often, self-extinguish, especially if the material beings to“char,” meaning that the material creates a carbonated barrier betweenthe flame and the underlying material.

In the gas phase, flammable gases released from the burning anddecomposing material are mixed with oxygen, which is supplied from theambient air. In the combustion zone, or the burning phase, fuel, oxygenand free radicals (i.e. H+, OH—, O—) 18 combine to create chemicalreactions that produce visible flames to appear. The fire then becomesself-sustaining because, as it continues to burn the material, moreflammable gases are released, feeding the combustion process.

In general, flame retardants, or fire inhabitants, act in three ways tostop the burning process, and consequently, can be classified by howthese agents work to stop a burning flame. These three methods of flameretardation/inhibition/extinguishing are described below:

-   -   (i) Disrupting the combustion stage of a fire cycle, including        avoiding or delaying “flashover,” or the burst of flames that        engulfs a room and makes it much more difficult to escape;    -   (ii) Limiting the process of decomposition by physically        insulating the available fuel sources from the material source        with a fire-resisting “char” layer; and    -   (iii) Diluting the flammable gases and oxygen concentrations in        the flame formation zone by emitting water, nitrogen or other        inert gases.

One highly effective family of prior art clean fire inhibiting chemicals(CFIC) has been supplied by PT. Hartindo Chemicatamata Industri ofJakarta, Indonesia (a/k/a Hartindo Anti Fire Chemicals) for many yearsnow, and used by many around the world in diverse anti-fireapplications. Current chemical formulations marketed by Hartindo underAF11, AF21 and AF31 product designations, disrupt the combustion stageof the fire cycle by combining with the free radicals (H+, OH—, O—) thatare produced during combustion.

Most prior art intumescent coatings, whether applied as paint orcoatings on engineered wood products (EWPs), work differently fromHartindo's fire inhibiting chemicals, in that such intumescent coatingsform a char layer when heated acting as an insulating layer to thesubstrate of fuel source, to prevent the fuel source from burning. Priorart Pyrotite® magnesium-based cementitious coatings, as used in LP'sFlameBlock® fire-rated OSB sheathing (i.e. sheeting) shown in FIG. 5B,FlameBlock® I-Joists shown in FIG. 6B, and other FlameBlock® EWPs,release water when exposed to the heat of a fire, and thereby dilute theflammable gases and oxygen concentrations in the flame formation zone.

Clearly, there is a great and growing demand for better, higherperformance, fire-rated building products for use in wood-framedbuildings in the single-family, multi-family and light commercialconstruction markets. Also, there is a great need for ways of designingand constructing high-density multi-story wood-framed buildings so thatsuch wood-framed building demonstrate improved defense and protectionagainst total fire destruction, while overcoming the shortcomings anddrawbacks of prior art methods and apparatus.

OBJECTS AND SUMMARY OF THE PRESENT INVENTION

Accordingly, a primary object of the present is to provide new andimproved method of and system for designing and constructinghigh-density multi-story wood-framed buildings so that such wood-framedbuilding demonstrates Class-A fire-protection and defense against totalfire destruction, while overcoming the shortcomings and drawbacks ofprior art methods and apparatus.

Another object of the present is to provide higher performancefire-rated building products for use in wood-framed buildings forsingle-family, multi-family, multi-story, as well as light commercialconstruction markets.

Another object of the present is to provide a novel system and methodthat addresses the epidemic of mid-rise building-under-constructionfires across the United States, where the media, lobbyists andpoliticians are blaming wood-framed construction, arson, and job siteaccidents as the main causes of such building fires.

Another object of the present is to provide a novel method of mitigatingthe risk of mid-rise building-under-construction fires caused during theframing stage, when wood-framed buildings are most vulnerable to fire,because are such buildings are constructed using small section lumber(2×4 and 2×6), trusses, and OSB sheathing, and fire fighters cannot getto the scene of such fires fast enough to extinguish the fire, and oncethey do, they can only minimize the damage to the surroundingstructures, and consequently, the damage caused is catastrophic and thedisruption to people's lives and surrounding businesses is tragic.

Another object of the present is to provide a novel method of designingand constructing multi-story wood-framed buildings so that suchwood-framed buildings demonstrate Class-A fire-protection and resistanceagainst total fire destruction.

Another object of the present is to provide a new and improved Class-Afire-protected oriented strand board (OSB) sheathing comprising a coremedium layer made of wood pump, binder and/or adhesive materials, a pairof OSB layers bonded to the core medium layer, a clean fire inhibitingchemical (CFIC) coatings deposited on the surface of each OSB layer andsides of the core medium layer, made from clean fire inhibiting chemical(CFIC) liquid solution applied to the surfaces by dipping the OSBsheathing into CFIC liquid in a dipping tank, allowing shallow surfaceabsorption or impregnation into the OSB layers and ends of the coremedium layer at atmospheric pressure, and thereafter, spraying amoisture, fire and UV radiation protection coating sprayed over the CFICcoating.

Another object of the present is to provide a Class-A fire-protectedfloor truss structure for installation in a wood-framed building housingone or more occupants, comprising: a set of lumber pieces treated withclean fire inhibiting chemical (CFIC) liquid to provide each the lumberpiece with a Class-A fire-suppression rating; and a set ofheat-resistant metal truss connector plates for connecting the treatedpieces of lumber together to form the fire-protected floor trussstructure; wherein each the heat-resistant metal truss connector plateis provided with a heat-resistant chemical coating deposited before themetal truss connector plate is used in constructing the fire-protectedfloor truss structure; and wherein the heat-resistant chemical coatingprovides significant reduction in heat transfer across theheat-resistant metal truss connector plate so as to significantly reduce(i) charring of wood behind the heat-resistant metal truss connectorplate in the presence of a fire in the building, (ii) disconnection ofthe treated lumber pieces from the heat-resistant metal truss connectorplate, and (iii) the risk of the fire-protected floor truss structurefailing during fire in the wood-framed building, and any putting atrisk, any of the occupants and any firemen trying to rescue theoccupants and/or extinguish the fire in the wood-framed building.

Another object of the present is to provide a Class-A fire-protectedfloor joist structure for installation in a wood-framed building housingone or more occupants, comprising: a floor joist made from lumbertreated with clean fire inhibiting chemical (CFIC) liquid to provide thejoist with a Class-A fire-suppression rating; and a set ofheat-resistant metal joist hangers for hanging the treated joist in thewood-framed building to form the fire-protected floor joist structure;wherein each the heat-resistant metal joist hanger is provided with aheat-resistant chemical coating deposited before the metal joist hangeris used in constructing the fire-protected floor joist structure; andwherein the heat-resistant chemical coating provides significantreduction in heat transfer across the heat-resistant metal joist hangerso as to significantly reduce (i) charring of wood behind theheat-resistant metal joist hanger in the presence of a fire in thebuilding, (ii) disconnection of the joist from the heat-resistant metaljoist hanger or lumber to which the heat-resistant metal joist hanger isconnected, and (iii) the risk of the fire-protected floor joiststructure failing during fire in the wood-framed building, and anyputting at risk, any of the occupants and any firemen trying to rescuethe occupants and/or extinguish the fire in the wood-framed building.

Another object of the present is to provide a factory for making Class-Afire-protected joist structures comprising: a first stage for dippinguntreated lumber components in a dipping tank filled with clean fireinhibiting chemicals (CFIC) liquid to coat the untreated lumbercomponents with liquid CFIC coating and form a Class-A fire treatedlumber components; a second stage for spraying metal joist hangers withheat-resistant chemical liquid to produce metal hanger joists having aheat-resistant coating; and a third stage for assembling the Class-Afire-protected lumber components together using the heat-resistant metaljoist plates so as to produce Class-A fire-protected joist structures.

Another object of the present is to provide a method of producing aClass-A fire-protected joist structure, comprising the steps: (a)producing a supply of water-based clean fire inhibiting chemical (CFIC)liquid; (b) filling a dipping tank with the supply of the water-basedCFPC liquid; (c) filling a reservoir tank connected to a liquid sprayingsystem with a quantity of heat-resistant chemical liquid; (d) dippinguntreated joist lumber beams into the dipping tank so as to apply acoating of CFIC liquid over all the surfaces of each joist lumber beamand allowing the CFIC-coated joist lumber beam to dry so as to produce aClass-A fire-protected joist lumber beam; (e) using the liquid sprayingsystem to coat metal joist hangers with heat-resistant chemical liquidin the reservoir tank, so as to produce heat-resistant metal joisthangers having a heat-resistant chemical coating, for use with theClass-A fire-protected joist lumber beams; (f) stacking and packagingone or more Class-A fire-protected joist lumber beams together into abundle, using banding or other fasteners, and with the heat-resistantmetal joist hangers, shipping the bundle and heat-resistant metal joisthangers to a destination site for use in construction of a wood-framedbuilding; and (g) assembling the Class-A fire-protected joist lumberbeams using the heat-resistant metal joist hangers so as to make aClass-A fire-protected joist structure in the wood-framed building.

Another object of the present is to provide a method of producingClass-A fire-protected finger-jointed lumber from an automated factoryhaving a production line with a plurality of stages, the methodcomprising the steps of: (a) providing a reservoir tank containing asupply of clean fire inhibiting chemical (CFIC) liquid that is suppliedto a dipping tank deployed in an in-line high-speed CFIC liquiddip-coating stage installed between (i) a lumber planing/dimensioningstage supplied by a finger-jointing stage, and (ii) an automatedstacking, packaging, wrapping and banding stage installed at the end ofthe production line; (b) continuously loading a supply of untreatedshort-length lumber onto a multi-staged conveyor-chain transportmechanism installed along and between the stages of the production line;(c) loading the untreated short-length lumber into a controlled-dryingstage so to produce suitably dried short-length lumber for supply to thefinger-jointing stage; (d) continuously supplying controllably-driedshort-length lumber into the finger-jointing stage for producing piecesof extended-length finger-jointed lumber in a highly-automated manner;(e) automatically transporting produced pieces of extended-lengthfinger-jointed lumber into the planing/dimensioning stage, so that thefinger-jointed lumber is planed/dimensioned into pieces of dimensionedfinger-jointed lumber, and outputted onto the multi-stage chain-drivenconveyor mechanism; (f) continuously transporting and submerging thedimensioned extended length finger-jointed lumber pieces through adipping tank for sufficient coating in CFIC liquid, while beingtransported on the conveyor-chain transport mechanism; (g) continuouslyremoving the wet dip-coated pieces of dimensioned finger-jointed lumberfrom the dipping tank, and automatically wet-stacking, packing, bandingand wrapping the dip-coated pieces together to produce a packaged bundleof fire-protected finger-jointed lumber while the CFIC liquid coating onthe dip-coated pieces of dimensioned finger-jointed lumber is still wet;(h) removing the packaged bundle of fire-protected finger-jointed lumberfrom the stacking, packaging, wrapping and banding stage, and storing ina storage location and allowed to dry; and (i) painting the ends of eachstacked and packaged bundle of fire-protected finger-jointed lumber,using a paint containing clean fire-inhibited chemicals (CFIC), andapplying trademarks and/or logos to the packaged bundle of Class-Afire-treated finger-jointed lumber.

Another object of the present is to provide an automated lumberproduction factory comprising: a production line supporting afinger-jointing stage, a planing and dimensioning stage, a clean fireinhibiting chemical (CFIC) dip-coating stage, and a stacking, packagingand wrapping stage, arranged in the order; wherein the production linesupports an automated production process including the steps of: (a)continuously fabricating finger-jointed lumber pieces at thefinger-jointing stage; (b) planing and dimensioning the finger-jointedlumber pieces at the planing and dimensioning stage; (c) after beingplaned and dimensioned, automatically conveying the finger-jointedlumber pieces from the planing and dimensioning stage to the CFICdip-coating stage in a high-speed manner; (d) dip-coating thefinger-jointed lumber pieces in a supply of clean fire inhibitingchemical (CFIC) liquid contained in a dipping tank maintained at theCFIC dip-coating stage, so as to produce Class-A fire-protectedfinger-jointed lumber pieces; and (e) stacking, packaging, wrapping andbanding a bundle of the Class-A fire-protected finger-jointed lumberpieces.

Another object of the present is to provide such an automated lumberproduction factory, wherein each finger-jointed lumber piece is afinger-jointed lumber stud, and each bundle of Class-A fire-protectedfinger-jointed lumber pieces is a bundle of Class-A fire-protectedfinger-jointed lumber studs for use in wood-framed buildingconstruction.

Another object of the present is to provide a novel in-line CFIC-liquiddip-coating and spray-coating stage/subsystem for installation along alumber production line in an automated lumber factory, for the rapidformation of a surface coating or surface film on the surface of eachpiece of LVL product dipped into a reservoir of CFIC liquid, and thenover-coated with a protective coating providing protection to moisture,UV radiation from the sun, and added fire-inhibition.

Another object of the present is to provide an automated factory systemfor producing Class-A fire-protected laminated veneer lumber (LVL)products in a high volume manner comprising: a stage for continuouslydelivering clipped veneer to the front of the LVL production line; aveneer drying stage for receiving veneers from the supply and drying toreach a target moisture content; a conveyor for conveying the componentsand LVL products along subsequent stages of the production line; anautomated veneer grading stage for automatically structurally andvisually grading veneers; a veneer scarfing stage for scarfing veneeredges to a uniform thickness at the joints between veneers, during thesubsequent laying-up stage and process; an adhesive application stagefor applying adhesive to the veneers; a lay-up stage for lifting veneersonto the processing line, and stacking and skew aligning the veneerswith adhesive coating until they are laid up into a veneer mat; apre-pressing stage for pressing the veneer mat together; a hot-pressingand curing stage for continuous hot pressing the veneer mat; across-cutting and rip sawing stage for cross-cutting and rip sawing theveneer mat into LVL products (e.g. studs, beams, rim boards and otherdimensioned LVL products); a print-marking system for marking each pieceof LVL product with a logo and grade for clear visual identification; aCFIC liquid dip-coating stage having a dipping reservoir through whichthe chain-driven conveyor transports LVL product into the dippingreservoir and along its length while submerged under CFIC liquid duringdip-coating operations, to form a CFIC coating on the surfaces of theLVL product, and removing the CFIC-coated LVL product from the dippingreservoir and wet-stacking and allow to dry; spray-coating aprotective-coating over the surface of the dried dip-coated LVL product,and transporting the LVL product to the next stage along the productionline; and a packaging and wrapping stage for stacking, packaging andwrapping the spray-coated/dip-coated LVL product.

Another object of the present is to provide such a new lumber factorysupporting an automated laminated veneer lumber (LVL) process comprisingthe steps of: (a) installing and operating a lumber production lineemploying a controlled drying stage, a veneer grading stage, a veneerscarfing stage, a veneer laying-up stage, a veneer laying-up stage, apre-pressing stage, a hot-pressing and curing stage, a cross-cutting andrip-sawing stage, an automated in-line dip-coating and spray-coatingstage, a print-marking and paint spraying stage, and an automatedpackaging and wrapping stage, installed along the lumber production linein named order; (b) continuously providing a supply clipped veneers ontoa conveyor installed along the lumber production line; (c) continuouslyproviding the veneers to the controlled drying stage so to producesuitably dried veneers for supply to the veneer grading stage; (d)scarfing dried veneers at the veneer scarfing stage to prepare for theveneer laying-up stage where the leading and trailing edges of eachsheet of veneer are scarfed to provide a flush joint when the veneersheets are joined together at the laying-up stage; (e) applying adhesivematerial to scarfed veneers prior to the veneer laying-up stage; (f)vacuum lifting veneers onto the processing line and stacked and skewaligned with adhesive coating until the veneers are laid up into aveneer mat of a predetermined number of veneer layers; (g) pressingtogether the veneer mat at the pre-pressing stage; (h) hot pressing theveneer mat in a hot-pressing/curing machine to produce an LVL mat at thehot-pressing and curing stage; (i) cross-cutting and rip-sawing theproduced LVL mat into LVL products (e.g. studs, beams, rim boards andother dimensioned LVL products) at the cross-cutting and rip sawingstage; (j) marking each piece of LVL product with a branded logo andgrade for clear visual identification at the print-marking and paintspraying stage; (k) continuously transporting and submerging thecross-cut/rip-sawed LVL product through a dipping reservoir containingclean fire inhibiting chemical (CFIC) liquid, at the dip-coating stageand then wet stacking and allowed to dry; (l) continuously spray-coatingthe dip-coated LVL products with a protective coating at, aspray-coating stage to produce Class-A fire-protected LVL products onthe production line; and (m) stacking, packaging and wrapping theClass-A fire-protected LVL product at the stacking, packaging andwrapping stage.

Another object of the present is to provide new and improved Class-Afire-protected oriented strand board (OSB) sheeting, spray-coated withclean fire inhibiting chemical (CFIC) liquid.

Another object of the present is to provide new and improved Class-Afire-protected oriented strand board (OSB) i-joist spray-coated withclean fire inhibiting chemical (CFIC) liquid.

Another object of the present is to provide a new and improvedfire-protected lumber roof trusses spray-coated with clean fireinhibiting chemical (CFIC) liquid.

Another object of the present is to provide new improved fire-protectedlumber top chord bearing floor truss (TCBT) structure, spray-coated withclean fire inhibiting chemical (CFIC) liquid.

Another object of the present is to provide a new and improvedfire-protected lumber floor joist structure, spray-coated with cleanfire inhibiting chemical (CFIC) liquid.

Another object of the present invention is to provide a new and improvedon-job-site method of spray treating wood, lumber, and engineered woodproducts (EWPs) with clean water-based fire inhibiting chemical (CFIC)that cling to the raw lumber and EPWs and acts as a flame retardant,preservative and water repellent, while improving the building's defenseagainst both accidental fire and arson attack, and reducing the risk offire to neighboring buildings should a fire occur in a wood framebuilding under construction.

Another object of the present invention is to provide new and improvedengineered wood products (EWP) using clean fire suppression technologiesto protect lumber and sheathing, without the shortcomings and drawbacksassociated with pressure treatment methods which are well known todestroy wood fibers, and lower the strength and performance of such woodproducts.

Another object of the present invention is to provide a new and improvedsystem for defending high-density multi-story wood-framed buildings fromfire during the design and construction phase, so that the risks ofwood-framed building burning down due to fire during construction issubstantially mitigated to the benefit of all parties.

Another object of the present invention is to provide a new and improvedmethod of protecting and defending multi-story wood-framed buildingsfrom fire by chemically defending from fire, 100% of the lumber used inwood-framed buildings.

Another object of the present invention is provide a new and improvedmethod of fire protecting multi-story wood-framed buildings from fire,by spraying coating, on the job site, before gypsum and wall board isinstalled over the framing, a clean fire inhibiting chemical (CFIC)liquid over all exposed surfaces of all lumber and wood products used inthe construction of the building, with that treats the raw lumber tobecome Class-A fire-protected.

Another object of the present is to provide a new and improved method ofprotecting wood-framed buildings from interior fires by spraying allexposed wood surfaces with clean fire inhibiting chemical (CFIC) liquidso as to achieve A-Class fire-protection throughout the entirewood-framed building.

Another object of the present invention is to provide a novel system andmethod of protecting multi-story wood-framed buildings against fire,when such structures are most vulnerable during the construction stage,involving the spraying of clean fire inhibiting chemical (CFIC) liquidover all interior surfaces of a wood-framed building being treated,including raw untreated lumber, EWPs, OSB sheathing, plywood, compositeboards, structural composite lumber and other materials, and trackingand certifying that each completed section of the wood-framed buildingwas properly spray coated with the environmentally clean fire inhibitingchemical, and has achieved Class-A fire-protection.

Another object of the present invention is to provide a novel method ofspray treating all surfaces of new raw/untreated and treated lumber andsheathing used to construct wood-framed multi-story buildings, usingclean fire inhibiting chemical s (CFIC) that cling to the surface ofwood during spray application and inhibit the start or ignition of afire as well as fire progression and flame spread, wherein the fireinhibitor can be sprayed using a back-pack sprayer, or floor-supportedpump sprayer system.

Another object of the present invention is to provide a novel method ofspray treating all surfaces of lumber and sheathing used to constructwood-framed multi-story buildings, during framing and sheathingoperations, floor by floor, with minor impact to the constructionschedule, while minimizing the builder's risk of fire, making protecting100% of the lumber in a building affordable.

Another object of the present is to provide an on-job-site spray systemfor coating of clean fire inhibiting liquid chemical (CFIC) liquid allover the interior surfaces of raw and treated lumber and sheathing usedin a completed section of a wood-framed assemblies in a wood-framedbuilding during its construction phase, wherein the on-job-site spraysystem comprises: a liquid spray pumping subsystem including a reservoirtank for containing a supply of CFIC liquid for spray-coating andtreating wood surfaces to provide Class-A fire-protection within thewood-framed building; a hand-held liquid spray gun, operably connectedto the reservoir tank using a sufficient length of flexible tubing, forholding in the hand of a spray-coating technician, and spraying CFICliquid from the reservoir tank onto the exposed interior wood surfacesof lumber and sheathing used to construct each completed section of awood-framed building construction, so as to form a CFIC coating on thetreated interior wood surfaces providing Class-A fire-protection; and aspray-certification system for visually marking and certifying theexposed interior wood surfaces of each completed section of thewood-framed building construction has been properly spray-coated toprovide Class-A fire-protection within each completed section of thewood-framed building.

Another object of the present is to providing new and improved methodsof and apparatus for protecting wood-framed buildings from wild fires byautomatically spraying water-based environmentally clean fire inhibitingchemical (CFIC) liquid over the exterior surfaces of the building,surrounding ground surfaces, shrubs, decking and the like, prior to wildfires reaching such buildings.

These and other benefits and advantages to be gained by using thefeatures of the present invention will become more apparent hereinafterand in the appended Claims to Invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Objects of the Present Invention will become more fullyunderstood when read in conjunction of the Detailed Description of theIllustrative Embodiments, and the appended Drawings, wherein:

FIG. 1A is an elevation view of architectural drawings prepared for aconventional multi-story high-density housing wood-framed building beingplanned for construction;

FIG. 1B is a plan view of architectural drawings prepared for theconventional multi-story high-density housing wood-framed buildingillustrated in FIG. 1A;

FIG. 2 is a perspective view of a 3D CAD-based geometrical buildingmodel of the conventional multi-story wood-framed building illustratedin FIGS. 1A and 1B, showing its multi-story wood-framed buildingstructure, with wood sheathing being removed for purposes ofillustration;

FIG. 3 is a photograph of a portion of the conventional multi-storywood-framed building of FIG. 2 under construction, with wood sheathingapplied to a portion of the wood-framed building structure;

FIG. 4 is a perspective view of a several beams of conventionaluntreated lumber used in constructing conventional multi-storywood-framed buildings;

FIG. 5A is a perspective view of a cut-away portion of a sheet ofconventional untreated OSB board used in sheathing wood-framedbuildings;

FIG. 5B is a perspective view of a cut-away portion of several sheets ofconventional fire-treated OSB board used in sheathing wood-framedbuildings;

FIG. 6A is a perspective view of a cut-away portion of severalconventional untreated OSB I-Joists used in the construction ofwood-framed buildings;

FIG. 6B is a perspective view of a cut-away portion of conventionalfire-treated OSB I-Joist used in the construction of wood-framedbuildings;

FIG. 7A is a perspective view of a several load bearing floor trusses(i.e. joints) constructed from untreated lumber connected usingconventional metal truss connector plates;

FIG. 7B is a perspective view of a cut-away portion of one of the floortrusses in FIG. 7A, showing a pair of conventional untreated lumberbeams connected together using a conventional metal truss connectorplate, as shown in FIGS. 8A and 8B;

FIG. 7C is a perspective view of a preassembled floor system, beinglifted into position on a multi-story wood-framed building, andconstructed from a plurality of floor truss structures constructed usinguntreated lumber beams connected together using conventional metalconnector plates;

FIG. 8A is perspective top view of conventional metal connector plate,showing its array of nail-spikes orthogonally projecting from itssupport plate;

FIG. 8B is perspective bottom view of conventional metal connectorplate, showing its array of nail-spikes orthogonally projecting from itssupport plate;

FIG. 9 is a perspective view of a plurality of conventional top chordload-bearing roof trusses, each being constructed from untreated lumberbeams connected together using conventional metal truss connectorplates, as shown in FIGS. 8A and 8B;

FIG. 10A is a table setting forth a summary of test samples in aconventional wood-framed building tested for fire resistance rating,flame passage, collapse time, and time of temperature rise, in theUnderwriters Laboratories (UL) Report dated 8 Sep. 2008 entitled“Structural Stability Of Engineered Lumber In Fire Conditions” (ProjectNumber: 07CA42520);

FIG. 10B is a table setting forth a summary of test results (ASTM E119)of the test samples identified in the table of FIG. 10A, in theUnderwriters Laboratories (UL) Report dated 8 Sep. 2008 entitled“Structural Stability Of Engineered Lumber In Fire Conditions” (ProjectNumber: 07CA42520);

FIG. 11 is table setting for time of failure of conventional unprotectedfloor assemblies during a wood-framed building fire with an openbasement doorway, and also during a wood-framed building fire with aclosed basement doorway;

FIG. 12 is a graphical representation of a wood bearing wall schedulefor a conventional multi-story wood-framed building under construction,indicating that fire-treated sheathing has been specified only for outerwall structures by the building architects;

FIG. 13 is a schematic construction diagram for a conventionalmulti-story wood-framed building under construction, indicating in boldlines, around the perimeter of the building, that fire-treated lumberand sheathing has been specified only for outer wall structures by thebuilding architects, consistent with the wood bearing wall scheduleshown in FIG. 12;

FIG. 14A is a photographic representation showing a conventionalmulti-story wood-framed building structure ablaze during itsconstruction phase, and ravaged by flames fueled by massive amounts ofuntreated lumber and OSB sheathing used to construct the same, inaccordance with conventional architectural building specifications;

FIG. 14B is a photographic representation showing the conventionalmulti-story wood-framed building structure of FIG. 14B, completelydestroyed by fire during its construction phase, with firemen continuingto apply water to cool down the destroyed site;

FIG. 15 is a photographic representation of a section of a conventionalroof truss and its lumber beams and metal connection plate, both charredand weakened during an interior fire within a conventional multi-storywood-framed building;

FIG. 16 is a schematic representation of the process of fire showing itsfour primary components and illustrating various pathways available forsuppressing fire within a wood-framed building and protecting the samefrom total destruction by fire;

FIG. 17 is high-level flow chart describing the primary steps involvedin the method of designing and constructing multi-story wood-framedbuildings in accordance with the principles of the present invention sothat such wood-framed building demonstrate improved fire resistancerating and protection against total fire destruction, comprising thesteps of (i) during the architectural design phase of a new multi-storybuilding, specifying fire-protected lumber, or raw untreated lumber,Class-A fire-protected OSB sheeting, Class-A fire-protected OSBi-joists, Class-A fire-protected floor trusses, Class-A fire-protectedroof trusses, and Class-A fire-protection on-job-site spray coatingtreatment of all lumber used on a building construction site; and (ii)during the construction phase, constructing the building in accordancewith the design specifications so as to provide a multi-storywood-framed building having Class-A fire-protection against total firedestruction;

FIG. 18 is a perspective view of a bundle of Class-A fire-protectedfinger-jointed lumber produced along the production line in theautomated fire-treated lumber factory illustrated in FIG. 19;

FIG. 19 is a perspective view of an automated lumber factory supportingan automated process for continuously fabricating Class-A fire-protectedfinger-jointed lumber products which, after the planning anddimensioning stage, are automatically dip-coated in a bath or reservoirof clean fire inhibiting chemical (CFIC) liquid, and then automaticallypackaged, stack-dried and wrapped in a high-speed and economical manner;

FIG. 19A is a perspective view of the high-speed CFIC dip-coating stagedepicted in FIG. 19, showing the various components used to implementthis subsystem along the production line of the automated lumberfactory;

FIGS. 20A and 20B, taken together, set forth a flow chart describing thehigh level steps carried out when practicing the method of producingClass-A fire-protected finger-jointed lumber pieces (e.g. studs orbeams) in the automated fire-treated lumber factory shown in FIGS. 19and 19A;

FIG. 21 is a schematic table representation illustrating the flamespread and smoke development indices obtained through testing of Class-Afire-protected lumber produced using the method of the illustrativeembodiment described in FIGS. 20A and 20B, and tested in accordance withtest standards ASTM E84 and UL 723;

FIG. 22 is a perspective view of a Class-A fire-protectedcross-laminated-timber (CLT) product (e.g. panel, stud, beam, etc.)fabricated along the production line of the automated lumber fabricationfactory shown in FIGS. 23 and 23A;

FIG. 23 is a perspective view of an automated lumber fabrication factorysupporting an automated process for continuously fabricatingcross-laminated timber (CLT) products which, after the planning anddimensioning stage, are automatically dip-coated in a bath of clean fireinhibiting chemical (CFIC) liquid, and then stacked, packaged andwrapped in a high-speed manner to produce Class-A fire-protected CLTproducts;

FIG. 23A is a perspective view of the automatic cross-laminated timber(CLT) dip-coating stage deployed along the production line of theautomated lumber fabrication factory shown in FIG. 23;

FIGS. 24A and 24B, taken together, set forth a flow chart describing thehigh level steps carried out when practicing the method of producingClass-A fire-protected cross-laminated timber (CLT) products in theautomated fire-treated lumber factory illustrated in FIGS. 23 and 23A;

FIG. 25 is a schematic table representation illustrating the flamespread and smoke development indices obtained through testing of Class-Afire-protected cross-laminated timber (CLT) product produced using themethod of the illustrative embodiment described in FIGS. 24A and 24B,and tested in accordance with the test standards ASTM E84 and UL 723;

FIG. 26 is a perspective view of Class-A fire-protected laminated veneerlumber (LVL) products, such as studs in load-bearing and nonload-bearing walls as well as in long-span roof and floor beams;

FIG. 27 is schematic representation of an automated lumber factory forfabricating Class-A fire-protected laminated veneer lumber (LVL)products along a multi-stage production line;

FIG. 27A is a perspective view of the automatic laminated veneer lumber(LVL) dip-coating stage deployed along the production line of theautomated lumber fabrication factory shown in FIG. 27;

FIG. 27B is a perspective view of the automatic laminated veneer lumber(LVL) spray-coating tunnel stage and drying tunnel stage deployed alongthe production line of the automated lumber fabrication factory shown inFIG. 27;

FIGS. 28A, 28B and 28C, taken together, set forth a flow chartdescribing the high level steps carried out when practicing the methodof producing Class-A fire-protected laminated veneer lumber (LVL) alongthe production line of the automated lumber factory shown in FIGS. 27,27A and 27B;

FIG. 29 is a table setting for flame spread and smoke developmentcharacteristics of Class-A fire-protected laminated veneer lumber (LVL)products (e.g. studs, beams, panels, etc.) produced using the method ofthe illustrative described in FIGS. 28A, 28B and 28C, and tested testingin accordance with the test standards ASTM E84 and UL 723;

FIG. 30 is a perspective of a cut-away portion of a piece of Class-Afire-protected oriented strand board (OSB) sheathing produced using themethod described in FIGS. 32A, 32B and 32C in the automated factoryshown in FIG. 33;

FIG. 31 is a cross-sectional schematic diagram of a section of theClass-A fire-protected OSB sheathing shown in FIG. 30, produced inaccordance with the present invention described in FIGS. 32 and 33;

FIGS. 32A, 32B and 32C, taken together, set forth a flow chartdescribing the high level steps carried out when practicing the methodof producing clean Class-A fire-protected OSB sheathing in accordancewith the present invention, comprising the steps of (a) in an automatedlumber factory, installing and operating a Class-A fire-protected lumberproduction line, supporting an edge painting stage, an CFIC liquid dipcoating stage, a spray coating tunnel stage and a drying tunnel,installed between the finishing stage and automated packaging andwrapping stage in the lumber factory, (b) sorting, soaking and debarkinglogs to prepare for the stranding stage, (c) processing the debarkedlogs to produce strands of wood having specific length, width andthickness, (d) collecting strands in large storage binds that allow forprecise metering into the dryers, (e) drying the strands to a targetmoisture content and screening them to remove small particles forrecycling, (f) coating the strands with resin and wax to enhance thefinished panel's resistance to moisture and water absorption, (g)forming cross-directional layers of strands into strand-based mats, (h)heating and pressing the mats to consolidate the strands and cure theresins to form a rigid dense structural oriented strand board (OSB)panel, (i) trimming and cutting the structural OSB panel to size, andmachining flooring and groove joints and applying edge sealants formoisture resistance, (j) applying Class-A fire-protective paint to theedges of the trimmed and cut OSB panels, (k) transporting and submergingOSB panels through the dipping tank of the dip coating stage forsufficient coating in CFIC liquid, while being transported on theconveyor-chain transport mechanism, (l) removing the wet dip-coated OSBpanels from the dipping tank, and wet stacking the OSB panels ininventory for about 24 hours or so, to allow the wet CFIC liquid coatingon the dipped OSB panels to penetrate into the panels and dry andproduce Class-A fire-protected OSB panels, (m) loading a stack ofdip-coated OSB panels to the second stage of the production line, (n)spray-coating the dip-coated OSB panels with a moisture, fire and UVprotection coating that supports weather during building constructionwhile protecting the Class-A fire protection properties of the OSBpanels, (o) transporting spray-coated dipped OSB sheets through a dryingtunnel, and (p) stacking, packaging and wrapping driedspray-coated/dipped OSB panels into a bundle of Class-A fire-protectedOSB panels or sheets (i.e. sheathing);

FIG. 33 is a schematic representation of the automated factoryconfigured for producing Class-A fire-protected OSB sheathing inaccordance with the principles of the present invention described inFIGS. 32A, 32B and 32C;

FIG. 33A is a perspective view of the automatic OSB sheathingdip-coating stage deployed along the production line of the automatedlumber fabrication factory shown in FIG. 33;

FIG. 33B is a perspective view of the automatic OSB sheathingspray-coating tunnel stage and drying tunnel stage deployed along theproduction line of the automated lumber fabrication factory shown inFIG. 33;

FIG. 34 are flame-spread rate and smoke-development indices associatedwith the Class-A fire-protected OSB sheathing of the present inventionproduced using the method of the illustrative embodiment described inFIGS. 32A, 32B and 32C, and tested in accordance with the test standardASTM E2768-11;

FIG. 35 is a perspective view of a Class-A fire-protected top chordbearing (floor) truss (TCBT) constructed in accordance with the methoddescribed in FIG. 36 in the automated factory illustrated in FIG. 37,using Class-A fire-protected lumber sections connected together usingheat-resistant coated metal truss connector plates, indicating a 50%reduction in heat transfer during ASTM E119 Testing, which reduces woodcharring behind the connector plates and prevented truss failure in thepresence of fire;

FIG. 36 is a flow chart describing the high level steps carried out whenpracticing the method of producing Class-A fire-protected top chordbearing floor trusses (TCBT) in accordance with the present invention,comprising the steps of (i) procuring a water-based clean fireinhibiting chemical (CFIC) liquid, (b) filling a dipping tank with thewater-based CFPC liquid, (c) filling the reservoir tank of an air-lessliquid spraying system with heat-resistant chemical liquid, (e) dippingstructural untreated lumber components into the dipping tank to apply acoating of clean fire inhibiting chemical (CFIC) over all its surfaces,and allow to dry to produce Class-A fire-protective lumber, and then useair-less liquid spraying system to coat metal connector plates for usewith the fire-treated lumber components, (f) assembling the fire-treatedlumber components using heat-resistant coated metal connector plates tomake a fire-protected top chord bearing floor truss (TCBT) structure,and (g) stacking and packaging one or more Class-A fire-protected floortruss structures using banding or other fasteners and ship todestination site for use in the construction of a wood-framed building;

FIG. 37 is a schematic representation of an automated factory for makingClass-A fire-protected floor trusses shown in FIG. 36 according to themethod described in FIG. 36, wherein the automated factory comprises thecomponents, including (a) a first stage for dipping untreated lumbercomponents in a tank filled with liquid clean fire inhibiting chemicals,(b) a second stage for spraying metal connector plates with a coating ofheat-resistant chemical liquid to produce heat-resistant metal connectorplates, and (c) third stage for assembling the Class-A fire-treatedlumber components with the heat-resistant metal connector plates to formClass-A fire-protected floor trusses;

FIG. 38 shows a family of Class-A fire-protected top chord bearing floorstructures constructed in accordance with the principles of the presentinvention, described in FIGS. 36 and 37;

FIG. 39 show a schematic table representation illustrating the flamespread and smoke development indices obtained through testing of Class-Afire-protected floor truss structure produced using the method of theillustrative embodiment described in FIGS. 36, 37 and 38, and tested inaccordance with standards ASTM E84 and UL 723;

FIG. 40 is a schematic representation of Class-A fire-protected topchord bearing roof truss structure of the present invention, constructedin accordance with the method described in FIG. 41 in the automatedfactory illustrated in FIG. 42, using Class-A fire-protected lumbersections connected together using heat-resistant coated metal trussconnector plates, indicating a 50% reduction in heat transfer duringASTM E119 Testing, which reduces charring in the wood behind theconnector plates and prevented truss failure in the presence of fire;

FIG. 41 is a flow chart describing the high level steps carried out whenpracticing the method of producing Class-A fire-protected top chordbearing roof trusses (TCBT) shown in FIG. 40, comprising the steps of(a) procuring clean fire inhibiting chemical (CFIC) liquid for treatingwood pieces, (b) filling water-based CFPC liquid into a dipping tank,(c) filling a reservoir tank of an air-less liquid spraying system withheat-resistant chemical liquid, (d) dipping structural untreated lumbercomponents into the dipping tank to apply a coating of clean fireinhibiting chemicals (CFIC) over all its surfaces, and allow to dry toproduce Class-A fire-protected lumber, (e) using the air-less liquidspraying system to coat the metal connector plates with heat-resistantchemical liquid, to produce heat-resistant metal connector plates foruse with the Class-A fire-protected lumber components, (f) assemblingthe fire-treated lumber components using heat-resistant Dectan chemicalcoated metal connector plates to make a fire-protected top chord bearingroof truss (TCBT) structure, and (g) stacking and packaging one or moreClass-A fire-protected roof truss structures using banding or otherfasteners and ship to destination site for use in constructionwood-framed buildings;

FIG. 42 is a schematic representation of an automated factory for makingClass-A fire-protected roof trusses in accordance with the methoddescribed in FIG. 41, wherein the factory comprises the components,including (a) a first stage for dipping untreated lumber components in adipping tank filled with liquid clean fire inhibiting chemicals (CFIC),(b) a second stage for spraying metal connector plates with aheat-resistant chemical to produce heat-resistant metal connectorplates, and (c) a third stage for assembling the Class-A fire-protectedlumber components with the heat-resistant metal connector plates to formClass-A fire-protected roof trusses;

FIGS. 43A and 43B show a family of Class-A fire-protected top chordbearing roof structures constructed in accordance with the presentinvention, described in FIGS. 40, 41 and 42;

FIG. 44 shows a schematic table representation illustrating the flamespread and smoke development indices obtained through testing of Class-Afire-protected roof truss structure produced using the method describedin FIGS. 41, 42, 43A and 43B, in accordance with ASTM E84 and UL 723;

FIG. 45 is a schematic representation of a Class-A fire-protected floorjoist structure of the present invention, formed using Class-Afire-protected lumber pieces connected together using heat-resistantmetal joist hanger plates, for use in construction a Class-Afire-protected floor joist system enabling the construction of one-hourfloor assemblies, using one layer of drywall, in long lengths (e.g. upto 40 feet), for spanning straight floor sections, and as a rim joist aswell;

FIG. 46 is a flow chart describing the high level steps carried out whenpracticing the method of producing Class-A fire-protected joiststructure in accordance with the present invention, comprising the stepsof (i) procuring clean fire inhibiting chemical (CFIC) liquid forfire-protecting wood and lumber, (b) filling water-based CFPC liquidinto a dipping tank, (c) filling the air-less liquid spraying systemwith heat-resistant chemical liquid, (d) dipping structural untreatedlumber components into dipping tank to apply a uniform coating of cleanfire inhibiting chemicals (CFIC) over all its surfaces, and allow to dryto produce Class-A fire-protected lumber, (e) using an air-less liquidspraying system to coat metal joist hangers with the heat-resistantchemical liquid, for use with the Class-A fire-protected lumbercomponents, (f) assembling the Class-A fire-protected lumber componentsusing heat-resistant coated metal joist hangers to make a Class-Afire-protected joist structure, and (g) stacking and packaging one ormore Class-A fire-protected joist structures using banding or otherfasteners and ship the package to destination site for use inconstruction of a wood-framed building;

FIG. 47 is a schematic representation of a factory for making Class-Afire-protected joist structures in accordance with the principles of thepresent invention, comprising the components, including (a) a firststage for dipping untreated lumber components in a tank filled withliquid clean fire inhibiting chemicals (CFIC), (b) a second stage forspraying metal joist hangers with heat-resistant chemical to as toproduce heat-resistant metal joist hangers, and (c) a third stage forassembling the Class-A fire-protected lumber components with theheat-resistant metal joist plates to form Class-A fire-protected joiststructures;

FIG. 48 shows a schematic table representation illustrating the flamespread and smoke development indices obtained through testing of Class-Afire-protected floor joist structure produced using the method of theillustrative embodiment described in FIGS. 46 and 47, tested inaccordance with standards ASTM E84 and UL 723;

FIG. 49 is a schematic representation illustrating the method of andsystem for the present invention for on-job-site spray-coating cleanfire inhibiting liquid chemical (CFIC) liquid over all exposed interiorsurfaces of raw as well as fire-treated lumber and sheathing used in acompleted section of a wood-framed building during its constructionphase, so as to deposit a thin CFIC film or coating over all exposedinterior wood surfaces, and thereby provide Class-A fire-protection overall lumber and sheathing used in the wood-framed building construction;

FIG. 50 is a schematic representation showing the primary components ofthe air-less liquid spraying system for spraying environmentally-cleanClass-A fire-protective liquid coatings, comprising (i) an air-less typeliquid spray pumping subsystem having a reservoir tank for containing avolume of clean fire inhibiting chemical (CFIC) liquid, (ii) a hand-heldliquid spray nozzle gun for holding in the hand of a spray-coatingtechnician, and (iii) a sufficient length of flexible tubing, preferablysupported on a carry-reel assembly, if necessary, for carrying the CFICliquid from the reservoir tank of the liquid spray pumping subsystem, tothe hand-held liquid spray gun during spraying operations carried outinside the wood-framed building during the construction phase of thebuilding project;

FIG. 51A is a perspective view of a first job-site of multi-apartmentwood-framed building under construction prepared and ready for cleanfire inhibiting chemical (CFIC) liquid spray coating treatment appliedin accordance with the principles of the present invention;

FIG. 51B is a perspective view of a second job-site of multi-apartmentwood-framed building under construction prepared and ready for cleanfire inhibiting chemical (CFIC) liquid spray coating treatment appliedin accordance with the principles of the present invention;

FIGS. 52A, 52B and 52C, taken together, set forth a high-level flowchart describing the steps carried out when practicing the method ofproducing Class-A fire-protected multi-story wood-framed buildingshaving improved resistance against total fire destruction, comprisingthe steps of (a) a fire-protection spray coating technician receives arequest from a builder to apply clean fire inhibiting chemical (CFIC)liquid coating on all interior surfaces of the untreated and/or treatedwood lumber and sheathing to be used to construct a wood-framedmulti-story building at a particular site location, (b) thefire-protection spray coating technician receives building constructionspecifications, analyze same to determine the square footage of cleanfire inhibiting chemical (CFIC) coating to be spray applied to theinterior surfaces of the wood-framed building, compute the quantity ofCFIC liquid required to do the spray job satisfactorily, and generate ajob price quote for the spray job and send to the builder for review andapproval, (c) after the builder accepts the job price quote, the builderorders the fire-protection spray coating team to begin performing theon-site wood coating spray job, in accordance with the buildingconstruction schedule, so that after the builder completes eachpredetermined section of the building, where wood framing has beenconstructed and sheathing installed, but before any wallboard has beeninstalled, clean fire-inhibiting chemical (CFIC) liquid is supplied toan airless liquid spraying system, for spray coating all interior woodsurfaces with a CFIC coating, (d) when the section of the building isspray coated with clean fire-protection chemical coating, the section iscertified and marked as certified for visual inspection, (e) as eachsection of the wood-framed building is constructed according to theconstruction schedule, the spray coating team continues to spray coatthe completed section, and certify and mark as certified each suchcompleted spray coated section of the building under construction, (f)when all sections of the building under construction have beencompletely spray coated with clean fire-inhibiting chemical (CFIC)liquid materials, and certified as such, the spray technicians removethe spray equipment from the building, and the builder proceeds to thenext stages of construction and completes the building constructionaccording to architectural and building specifications and plans, and(g) the spray technician then issues a certificate of completion withrespect to the application of clean fire inhibiting chemical (CFIC)liquid to all exposed wood surfaces on the interior of the wood-framedbuilding during its construction phase, thereby protecting the buildingfrom risk of total destruction by fire;

FIG. 53 is a method of operating an air-less liquid spraying system,shown in FIGS. 49 and 50, so that clean fire inhibiting chemical (CFIC)liquid is sprayed as a fire-protective liquid coating over all exposedinterior surfaces of lumber and sheathing used in a completed section ofthe wood-framed building under construction, wherein the methodcomprises the steps of (a) procuring clean fire inhibiting chemical(CFIC) liquid, (b) shipping the CFIC liquid to its destination on aspecified job site location, (c) loading the water-based CFIC liquidinto the reservoir tank of an air-less liquid spraying system, and (d)using a spray nozzle operably connected to the air-less liquid sprayingsystem to a spray apply a coating of CFIC liquid over all of theinterior surfaces of the section of wood-framed building to be spraytreated at any given phase of building construction; and

FIG. 54 shows a schematic table representation illustrating the flamespread and smoke development indices obtained through testing ofon-job-site CFIC spray-treated Class-A fire-protected lumber andsheathing produced using the method of the illustrative embodimentdescribed in FIGS. 45 through 49, and tested in accordance with standardASTM E2768-1.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS OF THE PRESENTINVENTION

Referring to the accompanying Drawings, like structures and elementsshown throughout the figures thereof shall be indicated with likereference numerals.

Specification Of Method Of Designing And Constructing Multi-StoryWood-Framed Buildings In Accordance With The Principles Of The PresentInvention So That Such Wood-Framed Building Demonstrate Class-AFire-Protection And Improved Resistance Against Total Fire Destruction

FIG. 17 describes the primary steps involved in the method of designingand constructing multi-story wood-framed buildings in accordance withthe principles of the present invention so that such wood-framedbuilding demonstrate Class-A fire-protection and resistance againsttotal fire destruction. As shown, the method comprises the two phases:an architectural design phase; and a building construction phase.

During the architectural design phase of a new multi-story building, thearchitect specifies the use of (i) Class-A fire-protected lumber, or rawuntreated lumber, Class-A fire-protected OSB sheeting, Class-Afire-protected OSB i-joists, Class-A fire-protected floor trusses, andClass-A fire-protected roof trusses, and (i) on-job-site Class-Afire-protected spray coating treatment of all raw/untreated and treatedlumber using CFIC liquid after each completed section of the wood-framedbuilding, so as to ensure that a Class-A fire-protection coating isdeposited or otherwise formed on the interior surface of all exposedwood surfaces within the wood-framed building under construction.

As shown in FIG. 17, during the design phase, the building architectspecifies the use of the on-job-site spray method and system of thepresent invention so that all (100%) of new construction lumber andsheathing used on the building is Class-A fire-protected with a CFICcoating or film, to prevent fire ignition and flame spread in thebuilding, during the construction phase, as well as after constructionof the building is completed. According to the present invention, thebuilding architect also specifies that factory-applied Class-Afire-protective lumber be used on exterior walls, exterior face of theroof, walls and floor sheathing, as it offers extra UV and moistureprotection, against the natural elements.

During the construction phase, the builder constructs the building inaccordance with the architect's design specifications so as to provide asingle-story or multi-story wood-framed building having Class-Afire-protection and improved resistance against total fire destruction.

In order to carry out the method described above, it will be helpful todescribe several new and improved methods of producing Class-Afire-protected lumber and wood-based building products in accordancewith the principles of the present invention. Each of these improvedbuilding products can be used in the practice of the method described inFIG. 17, in combination with the novel method of spray-treating lumberand sheathing inside a wood-framed building under construction, toprovide Class-A fire-protection as described in FIGS. 41 through 45.

Specification Of The Method Of And Apparatus For Producing A Bundle OfClass-A Fire-Protected Lumber Produced In Accordance With The PrinciplesOf The Present Invention

While most fires start small, they often spread rapidly onto surroundingflammable surfaces. Before long, the phenomenon of flash over occurs,where superheated gases cause a whole room to erupt into flame withinminutes. Class-A fire-protected lumber of the present invention, asshown in FIG. 18, bears a clear or transparent surface coating formed bydip-coating lumber pieces in clean fire inhibiting chemical (CFIC)liquid, preferably Hartindo AF21 Total Fire Inhibitor, developed byHartindo Chemicatama Industri of Jakarta, Indonesia, andcommercially-available from Newstar Chemicals (M) SDN. BHD of SelangorDarul Ehsan, Malaysia http://newstarchemicals.com/products.html. When sotreated, Class-A fire-protected lumber products will prevent flames fromspreading, and confine fire to the ignition source which can be readilyextinguished, or go out by itself.

The primary chemical constituents of Hartindo AF21 include: monoammoniumphosphate (MAP) (NH₄H₂PO₄); diammonium phosphate (DAP) (NH₄)₂HPO_(4,);ammonium sulphate (NH₄)₂SO₄; urea (CH₄N₂O); ammonium bromide (NH4Br);and tripotassium citrate C₆H₅K₃O₇. These chemicals are mixed togetherwith water to form a clear aqueous solution that isenvironmentally-friendly, non-toxic, but performs extremely well as atotal fire inhibitor. In the presence of a flame, the chemical moleculesin the CFIC-coating formed with Hartindo AF21 liquid on the surface ofthe fire-protected lumber, interferes with the free radicals (H+, OH—,O) involved in the free-radical chemical reactions within the combustionphase of a fire, and breaks these free-radical chemical reactions andextinguishes the fire's flames.

FIG. 18 shows a bundle of Class-A fire-protected finger-jointed lumber29 produced using the method of and apparatus of the present invention.FIG. 19 shows an automated lumber factory system 20 for continuouslyfabricating wrapped and packaged bundles of Class-A fire-protectedfinger-jointed lumber product 29 in a high-speed manner, in accordancewith the principles of the present invention. However, it is understoodthat this automated factory and production methods can be used to treatand protect solid wood and timber products, as well, so as to produceClass-A fire-protected solid wood products (e.g. studs, beams, boards,etc), as well as engineered wood products.

As shown in FIG. 19, the factory 20 comprises a number of automatedindustrial stages integrated together under automation and control ofcontroller 28, namely: a high-speed multi-stage lumber piececonveyor-chain mechanism 22 having 6 primary stages in the illustrativeembodiment shown in FIGS. 19 and 19A; a kiln-drying stage 23 receivingshort pieces of lumber 21 from a supply warehouse maintained in oraround the factory; a finger-jointing lumber processing stage 24, forprocessing short-length pieces of kiln-dried lumber and automaticallyfabricating extended-length finger-jointed pieces of lumber 29, asoutput from this stage; a lumber planing and dimensioning stage 25 forplaning and dimensioning enlongated pieces of finger-jointed lumber intolumber pieces having lengths and dimensions for the product applicationat hand (e.g. studs); an in-line high-speed continuous CFIC liquiddip-coating stage 26, as further detailed in FIG. 19A; an automatedstacking, packaging, wrapping and banding/strapping stage 27, from whichbundles of packaged, wrapped and strapped Class-A fire-protected lumberproduct are produced in a high-speed automated manner.

In general, the kiln-drying stage 23 can be implemented in differentways. One way is providing a drying room with heaters that can be drivenby electricity, natural or propane gas, and/or other combustible fuelswhich release heat energy required to dry short-length lumber piecesprior to the finger-joint wood processing stage. Batches of wood to betreated are loaded into the drying room and treated with heat energyover time to reduce the moisture content of the wood to a predeterminedlevel (e.g. 19% moisture). In alternative embodiments, the kiln-dryingstage 23 might be installed an elongated tunnel on the front end of theproduction line, having input and output ports, with one stage of theconveyor-chain mechanism 22 passing through the heating chamber, fromits input port to output port, allowing short-length lumber to bekiln-dried as it passes through the chamber along its conveyormechanism, in a speed-controlled and temperature-controlled manner.Other methods and apparatus can be used to realize this stage along thelumber production line, provided that the desired degree of moisturewithin the wood is removed at this stage of the process.

As illustrated in FIG. 19, the finger-jointing lumber processing stage24 can be configured as generally disclosed in US Patent ApplicationPublication Nos. US20070220825A1 and US20170138049A1, incorporatedherein by reference. In general, this stage involves roboticwood-working machinery, automation and programmable controls, well knownin the finger-jointing wood art, and transforms multiple smaller-piecesof kiln-dried lumber into an extended-length piece of finger-jointedlumber, which is then planed and dimensioned during the nextplanning/dimensioning stage of the production line. An example ofcommercial equipment that may be adapted for the finger-jointingprocessing stage 24 of the present invention may be the CRP 2500, CRP2750 or CRP 3000 Finger Jointing System from Conception R.P., Inc.,Quebec, Canada http://www.conceptionrp.com/fingerjointing-systems.

As illustrated in FIG. 19, the lumber planing and dimensioning stage 25includes wood planing equipment, such industrial band or rotary sawsdesigned to cut and dimension finger-jointed lumber pieces produced fromthe finger-jointing lumber processing stage 24, into lumber boards of aspecified dimension and thickness, in an highly programmed and automatedmanner.

As shown in FIG. 19A, the dip-coating stage 26 of the factory system 20comprises a number of components integrated together on the productionline with suitable automation and controls, namely: a multi-stagechain-driven conveyor subsystem 22, supporting several parallel sets ofchain-driven transport rails 22A1, 22A2 and 22A3, as shown, extendingfrom the planing and dimensioning stage 25 towards the dipping tank 26B,and then running inside and along the bottom of the dipping tank 26B,and then running out thereof towards the stacking, packing, wrapping andbanding/strapping stage 27, as shown, and having the capacity oftransporting extend-length finger-jointed lumber pieces (i.e. boards)having a length as long as 30 or so feet; a dipping reservoir 26B havinga width dimension to accommodate the width of the chain-driven conveyorrails 22A1, 22A2 and 22A3 mounted and running outside of and also withinthe dipping tank 26B, as shown, to transport up planed and dimensionedfinger-jointed lumber pieces 29A supported upon the chain-driven rails22A1, 22A2 and 22A3, while the boards are fully immersed and submergedat least 6 inches deep in CFIC liquid 26H contained in the dipping tank26B, while moving at high speed, such as 300 feet/minute through thedipping tank 26B during the CFIC dip-coating process of the presentinvention; electrically-powered driven motors 261 for driving thechain-driven conveyors 22A1, 22A2 and 22A3 under computer control totransport finger-jointed pieces of lumber from stage to stage along thelumber production line; a level sensor 26F for sensing the level of CFICliquid 26B in the dipping tank at any moment in time during productionline operation; a reservoir tank 26C for containing a large volume orsupply of CFIC liquid solution 26K; a computer controller 26G forcontrolling the conveyor subsystem 22, and an electric pump 26D forpumping CFIC liquid into the dipping tank 26B to maintain a constantsupply level during system operation in response to the liquid levelmeasured by the level sensor 26F.

The high-speed CFIC liquid dip-coating subsystem 26 shown in FIG. 19Amay also include additional apparatus including, for example, liquidheaters, circulation pumps and controls for (i) maintaining thetemperature of CFIC liquid solution in the dipping tank 26B, and (ii)controlling the circulation of CFIC liquid around submerged pieces offinger-jointed lumber 29A being transported through the dipping tank 26Bin a submerged manner during a CFIC coating process. Controlling suchdip-coating parameters may be used to control the amount and degree ofabsorption of CFIC liquid within the surface fibers of thefinger-jointed lumber 29A as it is rapidly transported through thedipping tank 26B between the lumber planing and dimensioning stage 25and the lumber stacking, packaging, wrapping and banding/strapping stage27 of the lumber production line. Notably, the dip coating process ofthe present invention allows for the rapid formation a surface coating,or surface barrier, on the surface of each piece of dipped lumber, andin the presence of the surfactant in the CFIC liquid in the dippingtank, shallow impregnation of CFIC liquid 26H to occur into the surfacefibers of each piece of lumber 29A near atmospheric pressure (i.e. below6 inches of liquid CFIC in the dipping tank) during the dip-coatedprocess according to the principles of the present invention. It isunderstood that drip pans may also be provided beyond the dipping tank26B, installed beneath the chain-driven conveyor subsystem arrangedbetween the dripping tank 26B and the stacking, packaging, wrapping andbanding/strapping stage 27, to recover excess CFIC liquid dripping fromthe dip-coated lumber pieces 29A and returning this recovered CFICliquid to the dipping tank 26B after appropriate filtering of the CFICliquid if and as necessary.

As illustrated in FIG. 19, the stacking, packaging, wrapping and bandingstage 27 includes equipment designed to automatically receiveCFIC-coated finger-jointed lumber pieces 29A while still dripping andwet from CFIC liquid 26H, and wet stacking a predetermined number oflumber pieces into a package, and then wrapping the package of lumberwith a sheet of wrapping material (e.g. TVEK or like material) thatcovers the top portion and at least half way down each side of thelumber package, and then banding or strapping the wrapped package withfiberglass or steel banding, well known in the art. The wrapping willtypically be preprinted with trademarks and logos of the lumbermanufacturer's brand. Finally, the ends of the lumber pieces in thestrapped, wrapped lumber package are painted with a fire-protectivepaint also containing CFIC liquid (e.g. Hartindo AF21 Total FireInhibitor) in amounts to be effective in Class-A fire suppression.

FIGS. 20A and 20B describe the high level steps carried out whenpracticing the method of producing bundles of Class-A fire-protectedfinger-jointed lumber 29 for use in fire-protected buildingconstruction.

As indicated at Block A in FIG. 20A, in an automated lumber factory, ahigh-speed Class-A fire-protected lumber production line is installedand operated, with a reservoir tank 26C containing a large supply ofclean fire inhibiting chemical (CFIC) liquid 26K (e.g. Hartindo AF21Total Fire Inhibitor) that is supplied to the automated CFIC liquiddip-coating stage 26 of the lumber factory 20, installed between (i) thelumber planing/dimensioning stage 25, and (ii) an automated stacking,packaging, wrapping and banding stage 27 in the lumber factory 20.

As indicated at Block B in FIG. 20A, a supply of untreated short-lengthlumber is loaded onto the high-speed conveyor-chain transport mechanism22 and auto-feeder installed along and between the stages of the lumberproduction line.

As indicated at Block C in FIG. 20A, the untreated short-length lumberis loaded into the controlled-drying stage 23 of the fire-protectedlumber production line so to produce suitably dried short-pieces oflumber for supply to the finger-jointing processing stage 24. This stagecan be performed by loading batches of short length lumber into thedrying room or oven, whose temperature and humidity are strictlycontrolled using electric heaters and other equipment under computercontrol. Alternatively, short-length lumber pieces can be controllablydried by moving batches of short-length lumber through a tunnel-likedrying room or chamber, through which chain-driven conveyor mechanism 22passes, like other stages along the lumber production line, while thetemperature and humidity of the environment is controlled usingelectric-driven or gas-combusting heaters under computer control in amanner well known in the art.

As indicated at Block D in FIG. 20A, the controllably-dried short-lengthlumber is continuously supplied into the finger-jointing lumberprocessing stage 24, for producing pieces of extended-lengthfinger-jointed lumber in a highly automated manner.

As indicated at Block E in FIG. 20B, produced pieces of extended-lengthfinger-jointed lumber are automatically transported to theplaning/dimensioning stage 25 so that the finger-jointed lumber can beplaned/dimensioned into pieces of dimensioned finger-jointed lumber 29A,and outputted onto the multi-stage conveyor-chain transport mechanism22.

As indicated at Block F in FIG. 20B, the dimensioned finger-jointedlumber pieces 29A are continuously transported and submerged through anautomated dipping tank 26B for sufficient coating in CFIC liquid (e.g.Hartindo AF21 liquid) while being transported on the conveyor-chaintransport mechanism 22.

As indicated at Block G in FIG. 20B, the wet dip-coated pieces ofdimensioned finger-jointed lumber are continuously removed from thedipping tank 26B, and automatically wet-stacking, packing, wrapping andbanding the wet dip-coated pieces into a packaged bundle of Class-Afire-protected finger-jointed lumber.

As indicated at Block H in FIG. 20B, the packaged bundle of Class-Afire-protected finger-jointed lumber is removed from the stacking,packaging, wrapping and banding stage 27 and stored in a storagelocation in the factory 20. The strapping the bundle material used maybe made of high-strength fiberglass plastic or metal banding material.

As indicated at Block I in FIG. 20B, the ends of each packaged bundle offire-protected dimensioned finger-jointed lumber 29, produced from theproduction line, are painted using a Class-A fire-protected paintcontaining clean fire-inhibited chemicals (CFIC) (e.g. 25% Hartindo AF21liquid, 75% liquid polymer binder, and black liquid pigment) andapplying trademarks and logos to the wrapped package of Class-Afire-protected finger-jointed lumber.

In the illustrative embodiment, Hartindo AF21 Total Fire Inhibitorliquid is used as the CFIC liquid 26H that is deposited as a CFICsurface coating during the dip-coating of wood/lumber products on theproduction line of the present invention described above. Thesurfactants in Hartindo AF21 liquid formulation break the surfacetension and allow its chemical molecules to impregnate ever so slightlythe surface of the treated wood. This way, in the presence of a flame,the chemical molecules in the CFIC-coating on the surface of thefire-protected lumber, interferes with the free radicals (H+, OH—, O—)produced during the combustion phase of a fire, and breaks the fire'schemical reaction and extinguishes its flame. This is a primary firesuppression mechanism implemented by the CFIC-coatings deposited on woodsurfaces in accordance with the various principles of inventiondisclosed and taught herein.

The table in FIG. 21 illustrates the flame spread and smoke developmentindices of fire-protected lumber 29 produced using the method of theillustrative embodiment, using Hartindo AF21 as a CFIC liquid dipcoating material, described in FIGS. 20A and 20B. As shown in the table,the flame spread index for Spruce Pine Fir (SPF) was measured to be 15,whereas the smoke development index measured to be 95. The flame spreadindex for Douglas Fir was measured to be 0, whereas the smokedevelopment index measured to be 40.

Specification Of The Method Of And Apparatus For Producing Class-AFire-Protected Cross-Laminated Timber (CLT) Panels In Accordance WithThe Principles Of The Present Invention

FIG. 22 shows a bundle of fire-protected cross-laminated timber (CLT)products (e.g. panels 42) produced using the method and apparatus of thepresent invention. The Class-A fire-protected cross-laminated timber(CLT) of the present invention 42 bears a surface coating of clean fireinhibiting chemical (CFIC) liquid (e.g. Hartindo AF21 Total FireInhibitor). This CFIC coating prevents flames from spreading by breakingthe free radical chemical reaction within the combustion phase of fire,and confining the fire to the ignition source which can be readilyextinguished, or go out by itself. When practicing the presentinvention, it is important that other fungicides, biocides, woodpreservatives, and/or mildew agents are not added to the CFIC solution39H (i.e. Hartindo AF21) in the CFIC dip coating tank 32B because it hasbeen discovered that such agents will chemically interfere with andadversely effect the fire-inhibiting properties and characteristics ofthe Hartindo AF21 fire-inhibiting chemicals, proven by E84 flame spreadtest results.

FIG. 23 shows an automated factory system 30 for producing Class-Afire-protected cross-laminated timber (CLT) panels, beams, and otherproducts 42 in a high volume manner. As shown in FIG. 23, the factory 30comprises a number of automated stages integrated together underautomation and control, namely: a multi-stage conveyor-chain mechanism32 having numerous primary stages in the illustrative embodiment shownin FIGS. 23 and 23A; a controlled-drying stage 33 receiving short piecesof lumber from a supply warehouse maintained in or around the factoryand drying them in a controlled manner well known in the art; afinger-jointing stage 34, for processing short-length pieces of driedtimber (i.e. lumber) and automatically fabricating extended-lengthfinger-jointed pieces of timber, as output from this stage; a laminationplaning stage 35 for planing finger-jointed pieces of timber to producefinger-jointed timber laminations; an automated adhesive stage 36 forapplying adhesive to the finger-jointed timer laminations; a pressingand curing stage 37 where the finger-jointed laminations with adhesiveare stacked in a cross-directional manner and then placed in pressingmachine where the adhesive is cured under pressure to produce across-laminated timber (CLT) panel, beam or other product; cross-cuttingand rip-sawing stage 38 for cutting and ripping cross-laminated timber(CLT) panels into CLT products 42A; a chain-driven conveyor 32 forconveying the CLT product 42A along the next few stages of theproduction line; an in-line CFIC liquid dip-coating stage 39, as furtherdetailed in FIG. 23A, supporting an elongated dipping tank 39B throughwhich the chain-driven conveyor 32 transports CLT product into thedipping tank 39H and along its length while submerged under CFIC liquid(e.g. Hartindo AF21 Total Fire Inhibitor) 39H during dip-coatingoperations, to form a CFIC coating on the surfaces of the CLT product,and removing the CFIC-coated CLT product from the dipping tank andtransport it to the next stage along the production line; a packagingand wrapping/labeling stage 40 for packaging and wrapping/labeling CLTproduct 42A either after it has dried, or while the CFIC-coated CLTproduct is still wet and allowed to dry in its wrapping.

In general, the controlled-drying stage 33 will include drying room withheaters that can be driven by electricity, natural or propane gas, orother combustible fuels which produce heat energy required to dryshort-length lumber prior to the finger-joint wood processing stage.Some alternative embodiments, the controlled-drying stage 33 might beinstalled on the front end of the production line as shown in FIG. 23,and having input and output ports, with one stage of the conveyor-chainmechanism 32 passing through the heating chamber, from its input port tooutput port, allowing short-length lumber to be kiln-dried as it passesthrough the chamber along its conveyor mechanism. Other methods andapparatus can be used to realize this stage of the lumber productionline of the present invention, provided that the desired degree ofmoisture within the wood is removed with heat or radiant energy at thisstage of the process.

As illustrated in FIG. 23, the finger-jointing lumber processing stage34 can be configured as generally disclosed in US Patent ApplicationPublication Nos. US20070220825A1 and US20170138049A1, incorporatedherein by reference. In general, this stage involves roboticwood-working machinery, automation and programmable controls, well knownin the finger-jointing wood art, and transforms multiple smaller-piecesof kiln-dried lumber into an extended-length piece of finger-jointedlumber, which is then planed and dimensioned during the nextplanning/dimensioning stage of the production line. An example ofcommercial equipment that may be adapted for the finger-jointingprocessing stage 34 of the present invention may be the CRP 2500, CRP2750 or CRP 3000 Finger Jointing System from Conception R.P., Inc.,Quebec, Canada http://www.conceptionrp.com/finger-jointing-systems.

As illustrated in FIG. 23, the laminating planing stage 35 includes woodlamination planing equipment, such industrial band or rotary sawsdesigned to cut, plane and dimension finger-jointed lumber piecesproduced from the finger-jointing stage 34, into finger-jointed timberlaminations of a specified dimension and thickness.

As illustrated in FIG. 23, the lamination planing stage 35 can berealized using a band or radial saw as may be required to producefinger-jointed laminations.

As illustrated in FIG. 23, the adhesive application stage 36 can berealized using automated adhesive applicators well known in the art toapply a predetermined controlled amount of adhesive to eachfinger-jointed timber lamination during the automated finger-jointingprocess.

As illustrated in FIG. 23, the pressing and curing stage 37 can berealized using an automated pressing and curing machine well known inthe art to apply a predetermined controlled amount of pressure to thetimber laminations after they have been cross-configured, and placedinto the machine for pressing and subsequent curing operations.

LEDINEK Engineering, do.o.o, of Hoce, Slovenia, offers complete turnkeyCLT production lines for high-volume automated production ofcross-laminated timber (CLT) panels. Such systems comprise: laminationplaners; finger jointing machines; presses & curing machines; andautomation and controllers. Such technologies and machines can be usedto implement many of the stages described above in the CLT panelproduction line of the present invention.https://www.ledinek.com/engineered-timber

As shown in FIG. 23A, the in-line high-speed continuous CFIC liquiddip-coating stage 39 of the production line comprises a number ofcomponents integrated together, with suitable automation and controls,namely: a multi-stage lumber board chain-driven conveyor subsystem 32,supporting several parallel sets of chain-driven transport rails 32A1,32A2 and 32A3, as shown, extending from the pressing and curing stage 39towards a dipping tank 39B, and then running inside and along the bottomof the dipping tank 39B, and then running out thereof, towards thepacking and wrapping stage 40, as shown, and having the capacity oftransporting CLT panels and boards having a length up to 30 or so feet.

In the illustrative embodiment, the dipping tank 39B has a widthdimension of 32 or so feet to accommodate the width of the CLT productbeing transported on chain-driven conveyor rails 32A1, 32A2 and 32A3mounted and running outside of and also within the dipping tank 39B, asshown. As shown, the CLT products 42A are supported upon the chaindriven rails 32A1, 32A2 and 32A3 while the CLT products are transportedthrough the dipping tank 39B while fully immersed and submerged at least6 inches deep in CFIC liquid 39H contained in the dipping tank 39B,moving lumber in and out of the dipping tank 39B in just a few secondsduring the CFIC dip-coating process of the present invention.Electrically-powered driven motors 39I are provided for the purpose ofdriving the chain-driven conveyors 32A1, 32A2 and 32A3 under computercontrol to transport CLT products 39E from stage to stage along theproduction line. A level sensor 39F is used for real-time sensing andcontrol of the liquid level of CFIC liquid 39H in the dipping tank 39Bat any moment in time during production line operation. A reservoir tank39C is provided for containing a large volume or supply of made up CFICliquid solution (e.g. Hartindo AF21 Total Fire Inhibitor). Also, acomputer controller 39G is used for controlling the conveyor subsystem32, and an electric pump 39D for pumping CFIC liquid into the dippingtank 39B to maintain a constant supply level during system operation inresponse to the liquid level measured by the level sensor 39F andsupplied to the control computer 39G.

The high-speed dip-coating subsystem 39 may also include additionalapparatus including, for example, liquid heaters, circulation pumps andcontrols for (i) maintaining the temperature of CFIC liquid solution inthe dipping tank 39B, and (ii) controlling the circulation of CFICliquid around submerged CLT product 39E being transported through thedipping tank in a submerged manner during a CFIC coating process.Controlling such dip coating parameters may be used to control theamount and degree of absorption of CFIC liquid within the surface fibersof the CLT product, as it is rapidly transported through the dippingtank 39B. Notably, the dip coating process allows for the rapidformation a surface coating, or surface barrier, on the surface of eachpiece of dipped CLT product 39E, and in the presence of a surfactant inthe CFIC liquid in the dipping tank 39B, shallow impregnation of CFICliquid 39H (e.g. Hartindo AF21) can occur into the surface fibers ofeach CLT piece 42A near atmospheric pressure (i.e. below 6 inches ofliquid CFIC in the dipping tank). It is understood that drip pans mayalso be provided beyond the dipping tank 39B, installed beneath thechain-driven conveyor subsystem 32 arranged between the dripping tank39B and the packaging and wrapping stage 40, so as to recover excessCFIC liquid dripping from the dip-coated lumber pieces and returningthis recovered CFIC liquid to the dipping tank 39B after appropriatefiltering of the CFIC liquid if and as necessary.

As illustrated in FIG. 23, the packaging and wrapping stage 40 includesequipment designed to receive CFIC-coated CLT product while stilldripping and wet from CFIC liquid, and wrapping the CLT product 42A witha sheet of wrapping material (e.g. TVEK or like material) that coversthe top portion and at least half way down each side of the CLT product,and then banding or strapping the wrapped package 42 with fiberglass orsteel banding, well known in the art. The wrapping will typically bepreprinted with trademarks and logos of the lumber manufacturer's brand.Finally, the ends of the lumber pieces in the strapped, wrapped lumberpackage 42 are painted with a fire-protective paint also containing CFICliquid material, in amounts to be effective in fire suppression.

FIGS. 24A and 24B describe the high level steps carried out whenpracticing the method of producing bundles of Class-A fire-protectedcross-laminated timber (CLT) 42 for use in fire-protected buildingconstruction.

As indicated at Block A in FIG. 24A, in an automated lumber factory, ahigh-speed Class-A fire-protected lumber production line is installedand operated, with a reservoir tank 39B containing a large supply ofclean fire inhibiting chemical (CFIC) liquid 39H that is continuouslysupplied to the automated high-speed CFIC liquid dip-coating stage 39 ofthe lumber factory, installed between (i) a cross-cutting and rip-sawingstage 38, and (ii) an automated stacking, packaging, wrapping andbanding/strapping stage 40 installed at the end of the production linein the factory.

As indicated at Block B in FIG. 24A, a supply of untreated short-lengthlumber is loaded onto the conveyor-chain transport mechanism 32installed along and between the stages of the production line.

As indicated at Block C in FIG. 24A, the untreated short-length lumberis loaded into the controlled-drying stage of the production line so toproduce suitably dried short-length lumber for supply to thefinger-jointing processing stage 34. This stage can be performed byloading batches of short length lumber into the drying room or oven,whose temperature and humidity are strictly controlled using electricheaters and other equipment under computer control. Alternatively,short-length lumber pieces can be controllably dried by moving batchesof short-length lumber through a tunnel-like drying room or chamber,through which chain-driven conveyor mechanism 32 passes, like otherstages along the lumber production line of the present invention, whilethe temperature and humidity of the environment is controlled usingelectric-driven or gas-combusting space heaters under computer controlin a manner well known in the art.

As indicated at Block D in FIG. 24A, the controllably-dried short-lengthlumber is continuously supplied into the finger-jointing stage 34, forproducing pieces of extended-length finger-jointed timber (lumber) in ahighly automated manner.

As indicated at Block E in FIG. 24B, pieces of extended lengthfinger-jointed timber are planed and dimensioned into pieces offinger-jointed timber laminations, and outputting the same onto theconveyor-chain transport mechanism 32.

As indicated at Block F in FIG. 24B, adhesive material is applied to thefinger-jointed timber laminations produced during Block E.

As indicated at Block G in FIG. 24B, at the pressing & curing stage 37,pressing a plurality of finger-jointed timber laminations together withapplied adhesive between the laminations, and then curing the adhesivelyjoined laminations to produce a cross-laminated timber (CLT) pieces.

As indicated at Block H in FIG. 24B, cross-laminated timber (CLT) piecesare planed and finished at the cross-cutting and rip-sawing stage 38,and outputting finished CLT product to the CFIC liquid dip coating stage39.

As indicated at Block I in FIG. 24B, the finished CLT products arecontinuously transported and submerged through the dipping tank 39B ofthe dip coating stage 39 for sufficient coating in CFIC liquid (e.g.Hartindo AF21 Total Fire Inhibitor) 39H, while being transported on theconveyor-chain transport mechanism 32.

As indicated at Block I in FIG. 24B, continuously removing the wetdip-coated cross-laminated timber (CLT) pieces are continuously removedfrom the dipping tank 39B, and automatically stacked, packaged andwrapped/labeled while wet with CFIC liquid coating, and allowed to drywithin the package wrapping.

In the illustrative embodiment, Hartindo AF21 Total Fire Inhibitor isused as the CFIC liquid solution 34H to form the CFIC surface coatingonto treated wood/lumber products produced on the production line of thefactory described above. The clinging agent in the Hartindo AF21 CFICliquid enables its chemical molecules to cling to the surface of theCFIC-coated wood, while its surfactants help to break the surfacetension and allow chemical molecules to impregnate ever so slightly thesurface of the treated wood. This way, in the presence of a flame, thechemical molecules in the CFIC-coating on the surface of thefire-protected lumber, interferes with the free radicals (H+, OH—, O—)of the chemical reaction produced within the combustion phase of a fire,and breaks the fire's chemical reaction and extinguishes its flame. Thisis a primary fire suppression mechanism deployed or rather implementedby the CFIC-coatings deposited on wood surfaces in accordance with thevarious principles of invention, disclosed and taught herein.

The table in FIG. 25 illustrates the flame spread and smoke developmentindices of fire-protected lumber produced using the method of theillustrative embodiment described in FIGS. 20A and 20B. As shown in thetable, the flame spread index for Spruce Pine Fir (SPF) was measured tobe 15, whereas the smoke development index measured to be 95. Theflame-spread index for Douglas fir was measured to be 0, whereas thesmoke development index measured to be 40.

Specification Of The Method Of And Apparatus For Producing Class-Afire-protected Laminated Veneer Lumber (LVL) Products (i.e. Studs andBoards) In Accordance With The Principles Of The Present Invention

In many ways, LVL (Laminated Veneer Lumber) beams, headers, columns andstuds provide a better alternative than traditional solid sawn lumberpieces, as such engineered wood products (EWPs) are a stronger, stiffer,more consistent and more predictable building material. Also, whencompared to similar sized sections, fire-protected LVL products cansupport heavier loads and allow greater spans than conventional lumber.Every LVL product is made from sheets of veneer. When these sheets arecombined into a continuous billet or piece of LVL, the effects of flawsin individual sheets are negated because they are spread throughout thecross-section of the billet, rather than being concentrated in specificlocations, such as is the case with sawn lumber. For example, a flaw ina single sheet of veneer laid up into a 15-ply mat or billet of LVL willeffectively be 1/15. The challenge facing LVL producers is how to makethe strongest possible LVL from their available raw material using smartgrading techniques to sort their veneers. LVL is produced and used in avariety of different lengths, thicknesses and widths. In general, theLVL process is based on a combination of continuous lay-up andcycle-type hot pressing that is suitable for the production of LVLproducts in all lengths.

FIG. 26 shows a stack of Class-A fire-protected laminated veneer lumber(LVL) products (i.e. beams, headers, columns, studs and rim boards) 57Aproduced using the method and automated factory system 45 shown in FIGS.27 and 27A. The Class-A fire-protected laminated veneer lumber (LVL)products 57A bear two coatings: (i) an under-layer surface-coating ofClass-A fire-protection provided by a dip-coating of CFICfire-inhibiting chemical (e.g. Hartindo AF21 Total Fire Inhibitor) whichis allowed to stack-dry (e.g. for 24 hours or so); and (ii) a top-layermoisture, fire and UV protective coating that is spray-coated over theCFIC dip-coated, using a spraying tunnel 55, to deposit a moisture, fireand UV protection coating over the Class-A fire-protection coating overthe LVL product.

In the illustrative embodiment, the top protective coating is formulatedas follows: 75% by volume of Dectan chemical by Hartindo Chemical; 25%by volume of Hartindo AF21 Total Fire Inhibitor; and 1.0-0.75[cups/gallon] ceramic microsphere dust mixed in as an additive, where 1cup=8.0 US fluid ounces. This rugged top protective coating, whichApplicant will trademark under Gator Skin™, protects the CFIC coating(e.g. Hartindo AF21 fire inhibitor coating) from being washed out underoutdoor weather conditions expected during building construction whenroof, wall and floor sheeting is exposed to and impacted by the naturalenvironment until the building is “dried in.”

FIG. 27 shows an automated factory system 45 for producing Class-Afire-protected laminated veneer lumber (LVL) products in a high volumemanner in accordance with the principles of the present invention. Asshown in FIG. 27, the factory 45 comprises a number of automated stagesintegrated together under automation and control, namely: aconveyor-chain mechanism 47 having numerous stages in the illustrativeembodiment shown in FIGS. 27 and 27A, and a stage for delivering clippedveneer to the front of the LVL production line. The stage that deliversthe continuous supply of clipped veneer is supported by five precedingstages, starting in the log yard, where veneer logs are delivered to thelog yard for the LVL process. There, the logs, graded A and J andsuitable for peeling, are debarked at a log debarking stage, and thenbathed in a hot bath at the hot log bath stage, to increase the coretemperature of the logs up to about 65 degrees Celsius. Such hot logbath equipment can be obtained from the Southern Cross Engineering Co.Then, at a lathe peeling stage, the wood lathe scans the log profileusing multiple lasers, then centers the log for the most efficientrecovery of material and peels the logs to a core diameter (e.g. 78 mmfor the Raute Wood Lathe) to produce peeled veneers. Raute Corporationof Nastola, Finland supplies lathe peeling equipment for this stage. Atthe clipping stage, the peeled veneers are clipped to a wet width ofapproximately 1.4 meters and then stacked according to their moisturecontent. Equipment for supporting this stage is supplied by Babcock &Wilcox.

As shown in FIG. 27, the LVL production line comprises, beyond itsveneer delivery stage, an arrangement of stages, namely: a veneer dryingstage 47 for receiving veneers from the supply and drying them in acontrolled manner using, for example, a Babcock BSH, 22 bar, steamheated, six deck, roller veneer drier, supporting three stages of dryingto reach a target moisture content of between 8 and 10%; a chain-drivenconveyor 47 for conveying the components and LVL products alongsubsequent stages of the production line; an automated veneer gradingstage 48 for automatically structurally and visually grading veneersusing a Babcock NovaScan 4000 camera for surface appearance, aMetriguard 2650 DFX for ultrasonic propagation time, and an Elliot BayCypress 2000 moisture detection system; a veneer scarfing stage 49 forscarfing veneer edges to a uniform thickness at the joints betweenveneers, during the subsequent laying-up stage and process; adhesiveapplication stage 50 for curtain coating veneers with phenolformaldehyde, an exterior grade adhesive, using a Koch (1400 mm curtaincoater, with adhesive resin supplied by Dynea NZ Ltd.; a lay-up stage(i.e. station) 51 for vacuum lifting veneers (core sheets, face sheetsand make-up sheets) onto the processing line according to the pressrecipe, and stacking and skew aligning the veneers with adhesive coatinguntil they are laid up into a veneer mat; a pre-pressing stage 52 forpressing the veneer mat together; a hot-pressing and curing stage 53 forcontinuous hot pressing (over an extending length (e.g. 40 meters) usinga Dieffenbacher hot press with hot oil platens to complete cure of theadhesive resin applied to the pressed veneers, and produce an LVL mathaving a length up to 18 m long in size, a width of up to 1.2 m, and athickness between 12 and 120 mm; a cross-cutting and rip sawing stage 53for cross-cutting and rip sawing the produced LVL mat into LVL productssuch as studs, beams, rim boards and other dimensioned LVL products; anoptional sanding stage, employing orbital sanders; an inkjetprint-marking and paint spraying system for marking each piece of LVLproduct (e.g. LVL stud, board etc.) an with a branded logo and grade forclear visual identification; a CFIC liquid dip-coating stage 54, asshown in FIG. 27A, having a dipping tank 54B through which thechain-driven conveyor 47 transports LVL product into the dipping tank54B and along its length while submerged under CFIC liquid 54H (e.g.Hartindo AFF21 Total Fire Inhibitor from Newstar Chemicals, of Malaysia,or Hartindo Chemicatama Industri of Indonesia) during dip-coatingoperations, so as to form a CFIC coating on the surfaces of the LVLproduct, and removing the CFIC-coated LVL product from the dipping tank,and wet-stacking the LVL product and setting aside to dry for 24 hoursor so to produce Class-A fire-protective LVL product 54E; a spray tunnel55 for spray-coating Class-A fire-protective LVL product 54E (feed withan auto-feeder) with a moisture, fire and UV protective coating whilethe LVL product is being passed through a spraying tunnel 55 in ahigh-speed manner, and then quick-dried in a drying tunnel 56 and thenpassed onto the final stage 57; a stacking, packaging andwrapping/labeling stage 57 using Dieffenbacher, Signode equipment, forpackaging and wrapping/labeling the Class-A fire-protected LVL productin its wrapping, ready for forklift handling. Notably, a liquid dye canbe added to the CFIC dip-coating liquid 54H without adversely effectingits chemical properties.

KALLESOE MACHINERY A/S of Bredgade, Denmark, offers complete turnkey LVLproduction lines for high-volume automated production of LVL products.Such systems comprise: presses & curing machines; automation andcontrollers. Such technologies and machines can be used to implementmany of the stages described above in the LVL product production line ofthe present invention.

As shown in FIG. 27A, the dip-coating stage 54 comprises a chain-drivenconveyor subsystem 47, supporting several parallel sets of chain-driventransport rails 47A1, 47A2 and 47A3 as shown, extending from thepressing and curing stage 53 towards a dipping tank 54B, and thenrunning inside and along the bottom of the dipping tank 54B, and thenrunning out thereof towards the stacking, packing and wrapping stage 57,as shown, having the capacity of handling studs and boards having alength up to 18 feet (6 m) or so, as the production application mayrequire.

In the illustrative embodiment, the dipping tank 55B has a widthdimension of up to 32 feet to accommodate the width of the LVL product54E being transported on chain-driven conveyor rails 47A1, 47A2 and 47A3mounted and running outside of and also within the dipping tank 54B, asshown, and allowing sufficient dwell time in the CFIC liquid 54H duringthe dip-coating process. As shown, the LVL products 54E are supportedupon the chain driven rails 47A1, 47A2 and 47A3 while the LVL products54E are transported through the dipping tank 54B while fully immersedand submerged at least 6 inches deep in CFIC liquid 54H contained in thedipping tank 54B, moving at the linear rate of 300 feet/minute throughthe dipping tank 54B during the CFIC dip-coating process of the presentinvention. Electrically-powered driven motors are provided for thepurpose of driving the chain-driven conveyors 47A1, 47A2, and 47A3 undercomputer control to transport LVL products along the production line. Alevel sensor 54F is used for real-time sensing the level of CFIC liquid54H in the dipping tank 54B during production line operation. Areservoir tank 54K is provided for containing a large volume or supplyof made up CFIC liquid 54H. Also, a computer controller 54G is used forcontrolling the conveyor subsystem 47, and an electric pump 54D isprovided for pumping CFIC liquid 54H into the dipping tank 54B tomaintain a constant supply level during system operation in response tothe liquid level measured by the level sensor 54F and controlled by thecontroller 54G.

The high-speed dip-coating stage 54 may also include additionalapparatus including, for example, liquid heaters, circulation pumps andcontrols for (i) maintaining the temperature of CFIC liquid solution 54Hin the dipping tank 54B, and (ii) controlling the circulation of CFICliquid around submerged LVL product 54E being transported through thedipping tank in a submerged manner during the CFIC dip-coating process.Controlling such dip coating parameters may be used to control theamount and degree of absorption of CFIC liquid within the surface fibersof the LVL product as it is rapidly transported through the dipping tank54B between the cross-cutting and rip-sawing stage 53 and the lumberpackaging and wrapping stage 57 of the production line.

Notably, the dip coating process of the present invention allows for therapid formation a surface coating, or surface barrier, on the surface ofeach piece of dipped LVL product, or in the presence of a surfactantadded to the CFIC liquid in the dipping tank 54B, shallow impregnationof CFIC liquid 54H to occur into the surface fibers of each LVL piece57A near atmospheric pressure (i.e. below 6 inches of liquid CFIC in thedipping tank) during the dip-coated process. It is understood that drippans may also be provided beyond the dipping tank 54B, installed beneaththe chain-driven conveyor subsystem 47 arranged between the drippingtank 54B and the packaging and wrapping stage 57 so as to recover excessCFIC liquid dripping from the dip-coated lumber pieces and returningthis recovered CFIC liquid to the dipping tank after appropriatefiltering of the CFIC liquid if and as necessary.

As shown in FIG. 27B, the moisture, fire and UV protection is providedusing the spray tunnel stage 55 deployed immediately after theCFIC-liquid dip-coating stage 54. As shown, the spray tunnel stage 55comprises: a storage tank 55A for storing a large supply ofmoisture/fire/UV-protective liquid chemical 55B; a spray tunnel 55C forsupporting an array of spray nozzles 55D arranged about the conveyorrails 55E1, 55E2 and 55E3, operably connected to a liquid pump 55Econnected to the storage tank 55A under controller 55F, to provide a 360degrees of spray coverage in the tunnel 55C, for spray-coatingdip-coated LVL products within a controlled plane ofmoisture/fire/UV-protection liquid sprayed to cover 100% of surfaces ofsuch LVL products 54E as they are being transported through the spraytunnel 55 at high-speed; and a drying tunnel stage 56 installed afterthe spray tunnel stage 55, for quick drying of spray-coated Class-Afire-protected LVL products, as they move through the drying tunnel 56towards the automated stacking, packaging and wrapping stage 57 underthe control of the subsystem controller 58. In the preferred embodiment,the moisture/fire/UV protection liquid 55B sprayed in the spray tunnel55 is formulated as follows: 25% by volume Hartindo AF21 liquid; 75% byvolume Dectan Chemical from Hartindo Chemicatama Industri of Indonesia,or its distributed Newstar Chemicals of Malaysia; and 1.0-0.75[cups/gallon] of Hy-Tech ceramic microsphere dust, as an additive.

As illustrated in FIG. 27, the automated stacking, packaging andwrapping stage 57 includes equipment designed to receive Class-Afire-protected LVL product 54E, automatically stack the fire-protectedLVL product, package and wrap the product within a sheet of wrappingmaterial (e.g. plastic, TVEK or other wrapping material) covering thetop portion and at least half way down each side of the LVL productpackage 59, and then banding or strapping the wrapped package 59 withfiberglass or steel banding, well known in the art. The wrapping willtypically be preprinted with trademarks and logos of the lumbermanufacturer's brand. Finally, the ends of the lumber pieces in thestrapped, wrapped lumber package 59 are painted with a Class-Afire-protective paint, also containing CFIC liquid material (e.g. 25% byvolume Hartindo AF21) to be effective in achieving Class-Afire-protection.

FIGS. 28A and 28B describe the high level steps carried out whenpracticing the method of producing bundles of Class-A fire-protectedlaminated veneer lumber (LVL) product for use in fire-protected buildingconstruction.

As indicated at Block A in FIG. 28A, a high-speed fire-protected lumberproduction line is installed and operated in an automated lumber factory45, provided with an automated high-speed dip-coating stage 54 andspray-coating stage 55 installed between (i) the cross-cutting andrip-sawing stage 53 of the production line, and (ii) an automatedstacking, packaging and wrapping stage 57 installed at the end of theproduction line in the lumber factory 45.

As indicated at Block B in FIG. 28A, a supply clipped veneers 46 iscontinuously loaded onto the conveyor/transport mechanism 47 installedalong the LVL production line.

As indicated at Block C in FIG. 28A, the veneers are continuouslyprovided to the controlled drying stage 47 of the production line so toproduce suitably dried veneers for supply to the veneer grading stage 49and subsequent stages.

As indicated at Block D in FIG. 28A, dried veneers are scarfed at theveneer scarfing stage 49 to prepare for the veneer laying-up stage 51where the leading and trailing edges of each sheet of veneer are scarfed(i.e. lapped-jointed) in order to provide a flush joint when the veneersheets are joined together at the laying-up stage of the LVL process.

As indicated at Block E in FIG. 28B, adhesive material is applied bycurtain coating at the adhesive application stage 50, to the surfaces ofscarfed veneers prior to the veneer laying-up stage.

As indicated at Block F in FIG. 28B, the veneers are vacuum lifted ontothe processing line and stacked and skew aligned with adhesive coatinguntil the veneers are laid up, at the veneer laying-up line 51, into aveneer mat of a predetermined number of veneer layers (i.e. ply).

As indicated at Block G in FIG. 28B, the veneer mat is pressed togetherat the pre-pressing stage 52 of the production line.

As indicated at Block H in FIG. 28B, the veneer mat is hot pressed in ahot-pressing/curing machine to produce an LVL mat at the hot-pressingand curing stage 53 of the production line.

As indicated at Block I in FIG. 28B, the produced LVL mat is cross-cutand rip-sawed into LVL products (such as studs, beams, rim boards andother dimensioned LVL products) 54E at the cross-cutting and rip sawingstage 53.

As indicated at Block J in FIG. 28B, each piece of LVL product (e.g. LVLstuds, boards, etc.) 54E is marked with a branded logo and grade forclear visual identification at the inkjet print-marking and paintspraying stage installed after the cross-cutting and rip-sawing stage53.

As indicated at Block K in FIG. 28B, the cross-cut/rip-sawed LVL product54E is continuously transported and submerged through the dippingreservoir 54B at the CFIC-liquid dip-coating stage 54 so as to applyCFIC liquid 54H to the surface of the dipped LVL product 54E at acoating coverage density of about 300 square feet per gallon of CFICliquid 54H (i.e. Hartindo AF21). The dip-coated LVL product 54E is thenwet-stacked in an automated manner using auto-stacking machinery, andthen set aside and allowed to dry for a predetermined period of time(e.g. 24 hours) before the stack of dip-coated LVL wood is returned tothe production line for continued processing. In the illustrativeembodiment, Hartindo AAF21 total fire-inhibitor is used as the CFICliquid solution 54H, for depositing the CFIC surface-coating ontotreated LVL products produced on the production line described above.The surfactants contained in the CFIC liquid helps to break the surfacetension and allow chemical molecules to impregnate ever so slightly thesurface of the treated LVL products, and produce a Class-Afire-protective LVL product 54E.

As indicated at Block L in FIG. 28C, the Class-A fire-protective LVLproducts 54E are continuously feed through the spray tunnel stage 55 forspray coating a moisture/fire/UV-protective liquid coating 55B over theentire surface as each dip-coated Class-A fire-protected LVL product(e.g. stud) 54E is feed through the spray tunnel 55.

As indicated at Block M in FIG. 28C, the Class-A fire-protected LVLproduct is quick-dried while being passed through the drying tunnel 56disposed immediately after the curtain-coating tunnel 55. This producesa Class-A fire-protective LVL product with a moisture//fire/UVprotective coating as it exits the production line, improving thedurability of the Class-A fire-protective LVL product when exposed tooutdoor weather conditions during the construction phase.

As indicated at Block N in FIG. 28B, Class-A fire-protective LVL product59 is automatically stacked, packaged and wrapped at the automatedstacking, packaging and wrapping stage 57, with trademarked wrapping,logos and the like.

In the presence of a flame, the chemical molecules in the CFIC-coatingon the surface of the Class-A fire-protected LVL lumber 54E interfereswith the free radicals (H+, OH—, O—) produced during the combustionphase of a fire, and breaks the fire's free-radical chemical reactionsand extinguishes its flame. This is a primary fire suppression mechanismimplemented by the CFIC-coatings deposited on wood surfaces inaccordance with the principles of invention, disclosed and taughtherein.

The table in FIG. 29 illustrates the flame spread and smoke developmentindices of Class-A fire-protected lumber produced using the methoddescribed in FIGS. 28A and 28B. As shown in the table, for Spruce PineFire (SPF), the flame spread index was measured to be 15, whereas thesmoke development index was measured to be 95, meeting the test criteriafor Class-A fire-protection rating. For Douglas Fir, the flame spreadindex was measured to be 0, whereas smoke development index was measuredto be 40, also meeting the test criteria for Class-A fire-protectionrating.

Specification Of Method Of Producing Clean Fire-Protected OrientedStrand Board (OSB) Sheathing Constructed In Accordance With ThePrinciples Of The Present Invention

FIGS. 30 and 31 show a piece of Class-A fire-protected oriented strandboard (OSB) sheathing 60 constructed in accordance with the principlesof the present invention. This Class-A fire-protected OSB sheathing 69is provided with a moisture, fire and UV protection coating 64 thatsupports weather during building construction when roof, wall and floorsheeting gets hammered by the natural environment until the building is“dried in.” The coating 64 also protects the CFIC (e.g. Hartindo AF21fire inhibitor) dip-coatings 63A and 63B and paint coating 63C fromgetting washed out by the weather during the construction phase, asotherwise occurs with most conventional pressure-treated lumberproducts.

As shown, the Class-A fire-protective OSB sheathing 60 comprises: a coremedium layer 61 made of wood pump, binder and/or adhesive materials; OSBsheathing layers 62A and 62B bonded to the core medium layer 61; a cleanfire inhibiting chemical (CFIC) coating 63C painted onto the edgesurfaces of the core medium layer 61, using a Class-A fire-protectivepaint containing a CFIC liquid; CFIC coatings 63A and 63B applied to thesurface of OSB sheathing layers 62A and 62B respectively, by dipping theOSB sheathing 66 into a CFIC liquid 66H contained in a dipping tank 66B,and allowing shallow surface absorption or impregnation into the OSBsheathing layers 62A and 62B at atmospheric pressure; and amoisture/fire/UV protective coating 64 spray-coated over the CFICcoatings 63A, 63B and 63C applied to protect these underlying CFICcoatings from outdoor weather conditions such as rain, snow and UVradiation from Sunlight.

In the illustrative embodiment, Hartindo AAF21 Total Fire Inhibitor isused as the CFIC liquid 66H to form the CFIC surface coatings 63A, 63Band 63C over the surfaces of the OSB product (e.g. sheet) 66. Theclinging agent in the CFIC liquid 66H enables its chemical molecules tocling to the surface of the CFIC-coated OSB product, while itssurfactants help to break the surface tension and allow chemicalmolecules to impregnate ever so slightly the surface of the treatedwood. The CFIC paint coating 63A can be formulated by adding HartindoAF21, 25-30% by volume, to a water-base paint containing liquid polymerbinder.

In the illustrative embodiment, the moisture/fire/UV protection liquid68A comprises a formulation comprising: 75% by volume, DECTAN chemicalliquid from Hartindo Chemicatama Industri of Jakarta, Indonesia, acomplex vinyl acrylic copolymer and tannic acid; 25% by volume, AF21anti-fire liquid chemical from Hartindo Chemicatama Industri; andceramic microsphere dust, 1.0-0.75 [cups/gallon] (e.g. ThermaCels™insulating ceramic microsphere dust by Hy-Tech Thermal Solutions, LLC,of Melbourne, Fla.).

FIG. 33 shows an automated factory system 65 for producing Class-Afire-protected laminated OSB products in a high volume manner inaccordance with the principles of the present invention. As shown inFIG. 33, the factory 65 comprises a number of automated stagesintegrated together under automation and control, namely: aconveyor-chain mechanism 65E having numerous primary stages in theillustrative embodiment shown in FIGS. 33, 33A and 33B.

As shown in FIG. 33, the OSB production line comprises an arrangement ofstages for high-volume automated production of OSB products. Suchsystems comprise: presses & curing machines; automation and controllers.Such technologies and machines can be used to implement many of thestages described above in the OSB product production line of the presentinvention. Suzhou CMT Engineering Company Limited offers completeturnkey OSB production lines.

As shown in FIG. 33A, the dip-coating stage 66 comprises a chain-drivenconveyor subsystem 65E, supporting several parallel sets of chain-driventransport rails 65E1, 65E2 and 65E3 as shown, extending from thepressing and curing stage 65H towards a dipping tank 54B, and thenrunning inside and along the bottom of the dipping tank 66B, and thenrunning out thereof towards the stacking, packing and wrapping stage65K, as shown.

In the illustrative embodiment, the dipping tank 66B has a widthdimension to accommodate the width of the OSB product 66E beingtransported on chain-driven conveyor rails 65E1, 65E2 and 65E3 mountedand running outside of and also within the dipping tank 66B, as shown,and allowing sufficient dwell time in the CFIC liquid 66H during thedip-coating process. As shown, the OSB products are supported upon thechain driven rails 65E1, 65E2 and 65E3 while the OSB products 66E aretransported through the dipping tank 66B while fully immersed andsubmerged at least 6 inches deep in CFIC liquid 66H contained in thedipping tank 66B, moving at the linear rate of 300 feet/minute throughthe dipping tank 66B during the CFIC dip-coating process of the presentinvention. Electrically-powered driven motors are provided for thepurpose of driving the chain-driven conveyors under computer control totransport OSB products 66E from stage to stage along the productionline. A level sensor 66F is used for sensing the level of CFIC liquid66H in the dipping tank at any moment in time during production lineoperation. A reservoir tank 66C is provided for containing a largevolume or supply of CFIC liquid 66H. Also, a computer controller 66G isused for controlling the conveyor subsystem, and an electric pump 66D isprovided for pumping CFIC liquid 66H into the dipping tank 66B tomaintain a constant supply level during system operation in response tothe liquid level measured by the level sensor 66F and controlled by thecontroller 66G.

The high-speed dip-coating stage 66 may also include additionalapparatus including, for example, liquid heaters, circulation pumps andcontrols for (i) maintaining the temperature of CFIC liquid solution inthe dipping tank 66B, and (ii) controlling the circulation of CFICliquid around submerged OSB product 66E being transported through thedipping tank in a submerged manner during the CFIC dip-coating process.Controlling such dip coating parameters may be used to control theamount and degree of absorption of CFIC liquid within the surface fibersof the OSB product 66E as it is rapidly transported through the dippingtank 66B between the cross-cutting and rip-sawing stage 65I and thelumber packaging and wrapping stage 65K of the production line. Notably,the dip coating process allows for the rapid formation a surfacecoating, or surface barrier, on the surface of each piece of dipped OSBproduct, or in the presence of a surfactant added to the CFIC liquid inthe dipping tank 66B, shallow impregnation of CFIC liquid 66H to occurinto the surface fibers of each OSB sheet 66E near atmospheric pressure(i.e. below 6 inches of liquid CFIC in the dipping tank) during thedip-coated process. It is understood that drip pans may also be providedbeyond the dipping tank 66B, installed beneath the chain-driven conveyorsubsystem arranged between the dripping tank 66B and the packaging andwrapping stage 65K so as to recover excess CFIC liquid dripping from thedip-coated lumber pieces and returning this recovered CFIC liquid to thedipping tank after appropriate filtering of the CFIC liquid if and asnecessary.

As shown in FIG. 33B, the moisture, fire and UV protection is providedusing the spray tunnel stage 67 deployed immediately after theCFIC-liquid dip-coating stage 66. As shown, the spray tunnel stage 67comprises: a storage tank 67A for storing a large supply ofmoisture/fire/UV-protective liquid chemical 67B; a spray tunnel 67C forsupporting an array of spray nozzles 67D arranged about the conveyorrails 67A1, 67A2 and 67A3, operably connected to a liquid pump 67Econnected to the storage tank 67A under controller 67F, to provide a 360degrees of spray coverage in the tunnel 67, for spray-coating dip-coatedOSB sheets 66E within a controlled plane of moisture/fire/UV-protectionliquid 67B sprayed to cover 100% of surfaces of such OSB sheets 66E asthey are being transported through the spray tunnel 67 at high-speed;and a drying tunnel stage 56 installed after the spray tunnel stage 67,for quick drying of spray-coated Class-A fire-protected OSB sheet 66E,as they move through the drying tunnel 68 towards the automatedstacking, packaging and wrapping stage 65K, under the control of thesubsystem controller 58. In the preferred embodiment, themoisture/fire/UV protection liquid 67B sprayed in the spray tunnel 67 isformulated as follows: 25% by volume Hartindo AF21 liquid; 75% by volumeDectan Chemical from Hartindo Chemicatama Industri of Indonesia, or itsdistributed Newstar Chemicals of Malaysia; and 0.75 [cups/gallon] ofHy-Tech ceramic microsphere dust, as an additive.

As illustrated in FIG. 33, the automated stacking, packaging andwrapping stage 65K includes equipment designed to receive Class-Afire-protected OSB sheets 66E, automatically stacking the fire-protectedOSB sheets, packaging and wrapping the sheets with wrapping material(e.g. plastic, TVEK or other wrapping material) that covers the topportion and at least half way down each side of the stacked OSB sheets,and then banding or strapping the wrapped package with fiberglass orsteel banding, well known in the art. The wrapping will typically bepreprinted with trademarks and logos of the lumber manufacturer's brand.Finally, the ends of the OSB lumber sheets 69 in the strapped, wrappedlumber package 69 are painted with a fire-protective paint alsocontaining CFIC liquid material (e.g. 25% by volume, Hartindo AF21liquid) to be effective in achieving Class-A fire-protection.

FIGS. 32A, 32B and 32C describe the high-level steps carried out whenproducing Class-A fire-protected OSB sheathing 69 in the automatedfactory shown in FIGS. 33, 33A and 33B, in accordance with the methodand principles of *the present invention.

Provided with this innovative two-coating system ofUV/moisture/fire-protection, in the presence of a flame, the chemicalmolecules in both the moisture/fire/UV-protective coating 64 andCFIC-coatings 63A, 63B capture the free radicals (H+, OH—, O) producedduring a fire, and break the fire's chemical reaction and extinguish itsflame. This is a primary fire suppression mechanism deployed or ratherimplemented by the CFIC-coatings deposited on wood surfaces inaccordance with the various principles of invention, disclosed andtaught herein.

As indicated at Block A in FIG. 32A, in an automated factory configuredfor automated production of Class-A fire-protected OSB sheeting, an edgepainting stage 65J, an CFIC liquid dip coating stage 67, a spray tunnelstage 67, and a drying tunnel stage 68 are installed between thefinishing stage 65I and automated packaging and wrapping stage 65K alongthe lumber production line.

As indicated at Block B in FIG. 32A, logs are sorted, soaked anddebarked at stage 65A to prepare for the logs for the stranding stage65B.

As indicated at Block C in FIG. 32A, the debarked logs are processed atthe stranding stage 65B to produce strands of wood having specificlength, width and thickness.

As indicated at Block D in FIG. 32A, at the strand metering stage 65C,the strands are collected in large storage binds that allow for precisemetering into the dryers.

As indicated at Block E in FIG. 32A, the strands are dried at the dryingstage 65D to a target moisture content and screening them to removesmall particles for recycling.

As indicated at Block F in FIG. 32B, the strands are coated with resinand wax at the blending 65F to enhance the finished panel's resistanceto moisture and water absorption.

As indicated at Block G in FIG. 32B, cross-directional layers of strandsare formed into strand-based mats at the mat forming stage 65G.

As indicated at Block H in FIG. 32B, the mats are heated and pressed atthe pressing and curing stage 65H to consolidate the strands and curethe resins and form a rigid dense structural oriented strand board (OSB)panel.

As indicated at Block I in FIG. 32B, at the finishing stage 65I, thestructural OSB panel is trimmed and cut to size, and groove jointsmachined and edge sealants applied for moisture resistance.

As indicated at Block J in FIG. 32B, Class-A fire-protective paint(containing CFIC liquid, 25% by volume, Hartindo AF21 liquid) is appliedto the edges of the trimmed and cut OSB panels, at the edge paintingstage 65J.

As indicated at Block K in FIG. 32B, OSB panels are transported andsubmerged through the dipping tank 66B of the dip coating stage 66 forsufficient coating in CFIC liquid 66H, while being transported on theconveyor-chain transport mechanism 65E.

As indicated at Block L in FIG. 32B, the wet dip-coated OSB panels areremoved from the dipping tank 66B, and wet stacked and set aside forabout 24 hours or so, to allow the wet CFIC liquid coating on the dippedOSB panels 66E to penetrate into the panels 69 as the coating dries.

As indicated at Block M in FIG. 32C, a stack of air-dried dip-coated OSBpanels 66E is loaded to the auto-feeder of the second stage of theproduction line, shown in FIG. 33B.

As indicated at Block N in FIG. 32C, the dip-coated OSB panels 66E arespray-coated with a moisture, fire and UV protection coating 64 thatsupports weather during building construction, to produce Class-Afire-protected OSB panels 69.

As indicated at Block O in FIG. 32C, spray-coated dipped OSB sheets 69are transported through a drying tunnel at stage 68.

As indicated at Block P in FIG. 32C, dried spray-coated/dipped OSBpanels 69 are stacked, packaged and wrapped into a bundle of Class-Afire-protected OSB panels at the stacking, packaging and wrapping stage65K.

As shown and described above, the lumber factory 65 is configured forproducing Class-A fire-protected OSB sheathing 69 fabricated inaccordance with the principles of the present invention.

FIG. 34 shows the flame-spread and smoke-reading (development)characteristics associated with the Class-A fire-protected OSB sheathing69 shown in FIGS. 30 and 31 and manufactured according to the method ofthe illustrative embodiment described in FIGS. 32A and 32B, and usingthe factory production line shown in FIGS. 33, 33A and 33B.

Specification Of Method Of Making Fire-Protected Top Chord Bearing(Floor) Truss (TCBT) Structure Constructed In Accordance With ThePrinciples Of The Present Invention

FIG. 35 shows a Class-A fire-protected top chord bearing (floor) truss(TCBT) structure 70 constructed in accordance with the presentinvention. As will be described in greater detail herein, the method ofproduction involves (i) producing Class-A fire-protected lumbersections, and (ii) producing heat-resistant metal truss connector plates10′ coated with Dectan-chemical (i.e. indicating a 50% reduction in E119Testing which reduces charring in the wood behind plate), and (iii)using these heat-resistant metal truss connector plates 10′ to secureconnect together the Class-A fire-protected pieces of lumber to form aClass-A fire-protected floor truss structure 70.

The Class-A fire-protected floor truss structure 70 performs better thanconventional I-joists, does not require doubling as do conventionalI-joists, does not require drilling on site top pass and installplumbing pipes and electrical wiring, as do I-joists, and does notrequire expensive LVL rim joists, while being easier to install inwood-framed buildings. The fire-protected floor truss structure 70 ofthe present invention provides an innovative solution to conventionalwooden floor trusses using metal nail connector plates to connecttogether small lumber sections which ignite easily and burn quickly in abuilding fire. During a building fire, conventional metal nail connectorplates 10, shown in FIGS. 8A and 8B, bend in the heat of a fire andrelease from its lumber section, causing the truss to loose all strengthin a fire, as shown in FIG. 15. This places occupants at great risktrying to escape a burning wood-framed building, as well as firementrying to extinguish a fire in a burning building before the firereaches its critical stage.

FIG. 36 describes practicing the method of producing Class-Afire-protected top chord bearing floor trusses (TCBT) 70 in accordancewith the present invention. As shown, the method comprises the steps:(a) procuring clean fire inhibiting chemical (CFIC) liquid 77A (e.g.Hartindo AF21 Total Fire Inhibitor from Newstar Chemicals); (b) fillingthe dipping tank 77 with water-based CFIC solution 77A; (c) filling thereservoir tank 78 of a liquid spraying system with a heat-resistantchemical liquid 78A for coating metal truss connector plates (e.g.Dectan Chemical from Hartindo Chemicatama Industri or its distributorNewstar Chemicals of Malaysia); (d) dipping structural untreated lumbercomponents into dipping tank 77 in a high-speed manner so as to apply acoating of clean fire inhibiting chemical (CFIC) 77A over all itssurfaces, wet-stacking the treated lumber, and allowing to air-dry toproduce Class-A fire-protected lumber sections 71A, 71B, 71C; (e) usingan air-less liquid spraying system, or other applicator, to coat metalconnector plates 10 with a heat-resistant chemical liquid (i.e. DectanChemical from Hartindo Chemicatama Industri) 78A and thereafter dryingin air or in drying tunnel, to produce heat-resistant metal connectorplates 10′ for use in connecting together the Class-A fire-protectedlumber components 71A, 71B, 71C; (f) assembling the Class-Afire-protected lumber components 71A, 71B, 71C using heat-resistantmetal connector plates 10′ spray-coated with Dectan chemical to make aClass-A fire-protected top chord bearing floor truss (TCBT) structure70; and (g) stacking and packaging one or more Class-A fire-protectedfloor truss structures 7 using banding, strapping or other fasteners andship to a destination site for use in constructing wood-framedbuildings.

Liquid DecTan chemical is a complex mixture of a vinyl acrylic copolymerand tannic acid. Liquid DecTan chemical from Hartindo Chemical Ltd. ofMalaysia has the ability to resist high heat, as it contains Hartindo'sAF21 total fire inhibitor, and has proven to be an excellentheat-resistant coating for purposes of the present invention. It can beapplied using spray-coating, curtain-coating, and brush-coating methods.

FIG. 37 depicts a factory 75 for making Class-A fire-protected floortrusses 70 in accordance with the principles of the present invention.As shown, the factory 75 comprises the components, including: (a) afirst stage 75A for automated dipping of untreated lumber components ina dipping tank 77 filled with clean fire inhibiting chemical (CFIC)liquid 77A (e.g. Hartindo AF21 Total Fire Inhibitor from NewstarChemicals of Malaysia) using automated dip-coating technology describedhereinabove in FIG. 19A; (b) a second stage 75B for automated sprayingmetal connector plates 10 with DecTan chemical 78A from HartindoChemicatama Industri using automated spray-coating technology describedhereinabove in FIG. 27B; and (c) a third stage 75C for automated orsemi-automated assembly of the Class-A fire-protected lumber components71A and 71B with the DecTan-coated heat-resistant metal connector plates10′ using automation and controls, to form Class-A fire-protected floortrusses 70 in a high-speed, high-volume manner.

FIG. 38 shows a family of fire-protected top chord bearing floorstructures 70A through 70H constructed in accordance with the presentinvention described above. Such examples include, for example: a bottomchord bearing on exterior frame or masonry wall 70A; a bottom chordbearing on exterior frame wall with masonry fascia wall 70B; anintermediate bearing—simple span trusses 70C; an intermediatebearing—continuous floor truss 70D; a header beam pocket—floor trusssupporting header beam 70E; an intermediate bearing—floor trusssupported by steel or wooden beam 70F; a top chord bearing on frame wall70G; and a top chord bearing on masonry wall 70H. Notably, in each ofthese alternative top chord bearing floor truss designs, heat-resistantmetal truss connector plates 10′ are used to connect sections offire-protected CFIC-coated lumber 71 in a secure manner, and enjoy themany benefits that such Class-A fire-protective building assembliesprovide over the prior art.

FIG. 39 shows a schematic table illustrating the flame spread and smokedevelopment indices obtained through testing of AAF21-treated Class-Afire-protected floor truss structures 70A through 70H produced using themethod of the illustrative embodiment described in FIGS. 35, 36 and 37,and tested in accordance with standards ASTM E84 and UL 723.

Specification Of The Method Of A Fire-Protected Top Chord Bearing (Roof)Truss Structure Of The Present Invention

FIG. 40 shows a Class-A fire-protected top chord bearing (roof) trussstructure of the present invention 80, formed using clean fireinhibiting chemical (CFIC) coated lumber pieces 81A through 81Econnected together using Dectan-coated heat-resistant metal trussconnector plates 10′. This novel building construction provides aninnovative solution to conventional wooden roof trusses employingconventional metal nail connector plates to connect together untreatedlumber sections used to construct the truss structure which are plaguedwith numerous problems: (i) lumber truss sections easily igniting andquickly burning in a building fire; and (ii) conventional metal nailconnector plates bending in the heat of a fire and releasing from itslumber sections, causing the truss structure to loose all strength in afire. Such problems put occupants at great risk trying to escape aburning building, and also firemen trying to extinguish the fire beforethe fire reaches its critical stage.

FIG. 41 describes practicing the method of producing Class-Afire-protected top chord bearing roof trusses (TCBT) 80 in accordancewith the present invention. As shown, the method comprises the steps:(a) procuring clean fire inhibiting chemical (CFIC) liquid 85A (e.g.Hartindo AF21 Total Fire Inhibitor from Newstar Chemicals); (b) fillingthe dipping tank 85 with water-based CFIC solution 86A; (c) filling thereservoir tank 86 of a liquid spraying system with a heat-resistantchemical liquid 86A for coating metal truss connector plates (e.g.Dectan Chemical from Hartindo Chemicatama Industri, or its distributorNewstar Chemicals of Malaysia); (d) dipping structural untreated lumbercomponents into dipping tank 85 in a high-speed manner so as to apply acoating of clean fire inhibiting chemical (CFIC) 85A over all itssurfaces, wet-stacking the treated lumber, and allowing to air-dry toproduce Class-A fire-protected lumber sections 81A, 81B, 81C, 81D, and81E; (e) using an air-less liquid spraying system, or other applicator,to coat metal connector plates 10 with a heat-resistant chemical liquid(i.e. Dectan Chemical) 8A and thereafter drying in air or in dryingtunnel, to produce heat-resistant metal connector plates 10′ for use inconnecting together the Class-A fire-protected lumber components 81A,81B, 81C, 81D, and 81E; (f) assembling the Class-A fire-protected lumbercomponents 81A, 81B, 81C, 81D, and 81E using heat-resistant metalconnector plates 10′ spray-coated with Dectan chemical to make a Class-Afire-protected top chord bearing roof truss (TCBT) structure 80; and (g)stacking and packaging one or more Class-A fire-protected roof trussstructures 80 using banding, strapping or other fasteners and ship to adestination site for use in constructing wood-framed buildings.

FIG. 42 depicted a factory 83 for making fire-protected top chordbearing roof trusses 80 in accordance with the principles of the presentinvention. As shown, the factory 83 comprises the components, including:(a) a first stage 83A for dipping untreated lumber components in adipping tank 85 filled with clean fire inhibiting chemical (CFIC) liquid85B (e.g. Hartindo AF21 Total Fire Inhibitor from Newstar Chemicals ofMalaysia) using automated dip-coating technology described hereinabovein FIG. 19A; (b) a second stage 83B for automated spraying metalconnector plates 10 with Dectan chemical 86A from Hartindo ChemicatamaIndustri, of Malaysia using automated spray-coating technology describedhereinabove in FIG. 27B, to produce heat-resistant metal connectorplates 10′; and (c) a third stage 83C for assembling the Class-Afire-protected lumber components 81A through 81E with the heat-resistantDectan-coated metal connector plates 10′ using automation and controls,to form fire-protected top chord bearing roof trusses 80 in ahigh-speed, high-volume manner.

FIGS. 43A and 43B show a family of fire-protected top chord bearing(roof) structures 80 constructed in accordance with the presentinvention and identified, for example, by roof top truss design names,including: kingpost 80A; double fink 80B; queen post 80C; double Howe80D; fink 80E; hip 80F; Howe 80G; scissors 80H; fan 80I; monopitch 80J;modified queenpost 80K; cambered 80L; dual pitch 80M; inverted 80N;gambrel 80O; piggyback 80P; polyensian 80Q; studio 80R; attic 80S;cathedral 80T; bowstring 80U; sloping flat 80V; stub 80W; and flat 80X.Notably, in each of these alternative top chord bearing roof trussdesigns, heat-resistant metal truss connector plates 10′ are used toconnect together sections of fire-protected CFIC-coated lumber sectionsin a secure manner, in accordance with the principles of the presentinvention, and enjoy the many benefits that such improved assemblyconstructions provide over the prior art.

FIG. 44 shows a schematic table illustrating the flame spread and smokedevelopment indices obtained through testing of AAF21-treated Class-Afire-protected roof truss structure 80A through 80X produced using themethod of the illustrative embodiment described in FIGS. 41 and 42, andtested in accordance with standards ASTM E84 and UL 723.

Specification Of A Method Of Producing A Class-A Fire-Protected FloorJoist Structure Of The Principles Of The Present Invention

FIG. 45 shows a Class-A fire-protected floor joist structure of thepresent invention 90, formed using clean fire inhibiting chemical (CFIC)coated lumber pieces 91A, 91B, and 93 connected together usingheat-resistant Dectan-coated metal joist hanger plates 92, and providinga solution to every firefighter's worse fear (i.e. sudden floorcollapses due conventional I-joists and floor trusses which can fail infire in as little as 6 minutes). The present invention provides a novelsolution to this dreaded problem by providing a Class-A fire-protectedfloor joist system that enables the construction of one-hour floorassemblies using one layer of drywall, available in long lengths (e.g.up to 40 feet), for spanning straight floor sections, and as providing arim joist as well.

FIG. 46 describes the high level steps carried out when practicing themethod of producing Class-A fire-protected joist structure 90 inaccordance with the present invention. As shown, the method of comprisesthe steps: (a) procuring clean fire inhibiting chemical (CFIC) liquid96A (e.g. Hartindo AF21 Total Fire Inhibitor from Newstar Chemicals);(b) filling the dipping tank 96 with water-based CFIC solution 96A; (c)filling the reservoir tank 98 of a liquid spraying system with aheat-resistant chemical liquid 98A (e.g. Dectan Chemical from HartindoChemicatama Industri, or its distributor Newstar Chemicals of Malaysia)for coating metal truss connector plates; (d) dipping structuraluntreated lumber components 91A, 91B, 93 into dipping tank 96 in ahigh-speed manner so as to apply a coating of clean fire inhibitingchemical (CFIC) 96A over all its surfaces, wet-stacking the treatedlumber, and allowing to air-dry to produce Class-A fire-protected lumbersections 91A′, 91B′, 93′; (e) dipping untreated structural joist lumberbeams 91A′, 91B′, 93′ into the dipping tank 96 so as to apply a uniformcoating of liquid clean fire inhibiting chemicals (CFIC) 96A over allits surfaces to form a CFIC-coating or membrane all over the lumbersurfaces, and allowing the CFIC-coated joist lumber beams to dry toproduce Class-A fire-protected lumber sections 91A, 91B, 93; and thenusing the air-less liquid spraying system to coat metal joist hangerswith liquid Dectan chemical 98A in the reservoir tank 98, so as toproduce heat-resistant Dectan-chemical coated metal joist hangers 92,for use with the Class-A fire-protected lumber components 91A, 91B and93; (f) stacking and packaging one or more fire-protected joist lumberbeams 91A, 91B, and 93 together into a bundle, using banding or otherfasteners, and with the heat-resistant metal joist hangers 92, andshipping the lumber bundle and heat-resistant metal joist hangers todestination site for use in construction wood-framed buildings; and (g)assembling the Class-A fire-protected joist lumber beams 91A, 91B and 93using the heat-resistant Dectan-chemical coated metal joist hangers 92to make a Class-A fire-protected joist structure 47 according to theprinciples of the present invention.

FIG. 47 depicts a factory 94 for making Class-A fire-protected joiststructures 90 in accordance with the principles of the presentinvention. As shown, the factory 94 comprises the components, including:(a) a first stage 94A for dipping untreated lumber components in adipping tank 96 filled with liquid clean fire inhibiting chemicals(CFIC) 96A (e.g. Hartindo AF21 Total Fire Inhibitor from NewstarChemicals) using automated dip-coating technology described hereinabovein FIG. 19A; (b) a second stage 94B for automated spraying metal joisthangers 92 with heat-resistant liquid Dectan chemical 98A from HartindoChemicatama Industri using automated spray-coating technology describedhereinabove in FIG. 27B to produce heat-resistant Dectan-coated metalhanger joists 92; and (c) a third stage 94C for automated orsemi-automated assembly of the Class-A fire-protected lumber components91A, 91B together using the Dectan-coated metal joist plates 92′ usingautomation and controls, to form Class-A fire-protected joist structures90 according to the present invention.

FIG. 48 shows a table illustrating the flame spread and smokedevelopment indices obtained through testing of AAF21-treated Class-Afire-protected floor joist structure 90 produced using the method of theillustrative embodiment described in FIGS. 46 and 47, and tested inaccordance with standards ASTM E84 and UL 723.

Specification Of The On-Job-Site Spray-Coating Based Method Of AndSystem For Class-A Fire-Protection Of All Exposed Interior Surfaces OfLumber And Sheathing Used In Wood-Framed Buildings During TheConstruction Phase

FIG. 49 illustrates an on-job-site spray coating of clean fireinhibiting liquid chemicals (CFIC) all over the exposed interiorsurfaces of raw and treated lumber and sheathing used in a completedsection of a wood-framed assemblies in a wood-framed building during itsconstruction phase.

As shown in FIGS. 49 and 50, the primary components of the air-lessliquid spraying system 100 comprises: (i) an air-less liquid spraypumping subsystem 101 including a reservoir tank 101B for containing asupply of liquid CFIC chemical 101C (i.e. AAF31 from Hartindo ChemicalLtd), (ii) a hand-held liquid spray nozzle gun 103 for holding in thehand of a spray coating technician, and (iii) a sufficient length offlexible tubing 102, on a carry-reel assembly, if necessary, forcarrying liquid CFIC solution from the reservoir tank 101B of thepumping subsystem 101A to the hand-held liquid spray nozzle gun 103during spraying operations carried out in the wood-framed buildingconstruction.

In general, any commercially-grade airless liquid spraying system may beused to spray fire-protective coatings on wood-framed buildingconstruction sites, and practice the method and system of the presentinvention, with excellent results. Many different kinds of commercialspray coating systems may be used to practice the present invention, andeach may employ an electric motor or air-compressor to drive its liquidpump. For purposes of illustration only, the following commercial spraysystems are identified as follows: the Xtreme XL™ Electric Airless SpraySystem available from Graco, Inc. of Minneapolis, Minn.; and the BinksMX412 Air-Assisted/Compressor-Driven Airless Spray System from CarlisleFluid Technologies, of Scottsdale, Ariz.

Countless on-site locations will exist having various sizes andconfigurations requiring the on-job-site spray-based fire-protectionmethod of the present invention. FIG. 51A illustrates a first job-siteof multi-apartment wood-framed building under construction prepared andready for clean fire inhibiting chemical spray coating treatment inaccordance with the principles of the present invention. FIG. 51Billustrates a second job-site of multi-apartment wood-framed buildingunder construction prepared and ready for clean fire inhibiting chemicalspray coating treatment in accordance with the principles of the presentinvention.

The on-job-site spray method and system involves spraying a clean fireinhibiting chemical (CFIC) liquid on all new construction lumber andsheathing to prevent fire ignition and flame spread. The method alsorecommends spraying exterior walls or the exterior face of the roof,wall and floor sheathing with CFIC liquid. The method further recommendsthat factory-applied fire-protective lumber be used on exterior walls,and fire-protected sheathing be used on the exterior face of the roof,wall and floor sheathing, as it offers extra UV and moisture protection.As disclosed herein, there are many different options available toarchitects and builders to meet such requirements within the scope andspirit of the present invention disclosed herein.

In the illustrative embodiment, Hartindo AF31 Total Fire Inhibitor (fromHartindo Chemical of Jakarta, Indonesia http://hartindo.co.id, or itsdistributor Newstar Chemicals of Malaysia) is used as the CFIC liquid101C to spray-deposit the CFIC surface coating onto treated wood/lumberand sheathing products inside the wood-framed building underconstruction. A liquid dye of a preferred color from Sun ChemicalCorporation http://www.sunchemical.com can be added to Hartindo AF31liquid to help the spray technicians visually track where CFIC liquidhas been sprayed on wood surfaces during the method of treatment. Theclinging agent in this CFIC liquid formulation (i.e. Hartindo AF31liquid) enables its chemical molecules to cling to the surface of theCFIC-coated wood so that it is quick to defend and break the combustionphase of fires (i.e. interfere with the free radicals drivingcombustion) during construction and before drywall and sprinklers canoffer any defense against fire. However, a polymer liquid binder,available from many manufacturers (e.g. BASF, Polycarb, Inc.) can beadded as additional cling agent to Hartindo AF31 liquid, in a proportionof 1-10% by volume to 99-90% Hartindo AF31 liquid, so as to improve thecling factor of the CFIC liquid when being sprayed in high humidityjob-site environments. Alternatively, liquid DecTan Chemical fromHartindo Chemical, which contains a mixture of vinyl acrylic copolymerand tannic acid, can be used a cling agent as well when mixed the sameproportions, as well as an additional UV and moisture defense onexterior applications. These proportions can be adjusted as required toachieve the cling factor required in any given building environmentwhere the spray coating method of the present invention is beingpracticed. This way, in the presence of a flame, the chemical moleculesin the CFIC-coating on the surface of the fire-protected lumber,interfere with the chemical reactions involving the free radicals (H+,OH—, O—) produced during the combustion phase of a fire, and break thefire's chemical reaction and extinguish its flame. This is a primaryfire suppression mechanism deployed or rather implemented by theCFIC-coatings deposited on wood surfaces in accordance with the variousprinciples of invention, disclosed and taught herein.

Specification Of Method Of Producing Multi-Story Wood-Framed BuildingsHaving Class-A Fire-Protection And Improved Resistance Against TotalFire Destruction

FIGS. 52A, 52B and 52C, taken together, set forth a high-level for chartdescribing the steps carried out when practicing the method of producingmulti-story wood-framed buildings having improved fire resistance ratingand protection against total fire destruction. The method comprises aseries of steps described below which effectively results in the coatingof substantially all exposed interior wood surfaces of the raw untreatedas well as fire-treated lumber and sheathing used during theconstruction phase of the wood-framed building, to protect and defendits wood, lumber and sheathing from ravage of fire and prevent totaldestruction by fire. The method recommends use of (i) the fire-protectedOSB sheathing shown in FIGS. 30 through 32 and described herein for theexterior face of the roof, wall and floor sheathing, and (ii) thefire-protected lumber products shown in FIGS. 18-21, 22-25, and 26-29,and described herein for interior and exterior wall studs, trusses,sills, and other wood-frame related building structures.

The spray-coating fire-treatment process of the present invention may becarried out as follows. Spray-coating technicians (i) appear on the newconstruction job-site after each floor (i.e. wood-framed buildingsection) has been constructed with wood framing and sheathing; (ii)spray liquid CFIC solution over substantially all of the exposedinterior surfaces of the wood, lumber and sheathing used in thecompleted wood-framed building section; and then (iii) certify that eachsuch wood-framed building section has been properly spray-coat protectedwith CFIC liquid chemicals in accordance with the principles of thepresent invention. Details of this method will be described in greaterdetail below in a step-by-step manner.

As indicated at Block A in FIG. 52A, the first step of the methodinvolves fire-protection spray-coating technician to receives a requestfrom a builder to spray a clean fire inhibiting chemical (CFIC) liquidcoating over substantially all exposed interior surfaces of theuntreated and/or treated wood lumber and sheathing used to construct acompleted wood-framed section of a building under construction at aparticular site location. This order could come in the form of a writtenwork order, and email message, or other form of communication, withappropriate documentation.

As indicated at Block B in FIG. 52A, the second step of the methodinvolves the fire-protection spray-coating technician (i) receivingbuilding construction specifications from the builder, architect and/orbuilding owner, (ii) analyzing same to determine the square footage ofclean fire inhibiting chemical (CFIC) liquid coating to be spray appliedto the interior surfaces of the wood-frame building, (iii) computing thequantity of clean fire inhibiting chemical material required to do thespray job satisfactorily, and (iv) generating a price quote for thespray job and sending the quote to the builder for review and approval.

As indicated at Block C in FIG. 52A, the third step of the methodinvolves,. after the builder accepts the price quote, the builder ordersthe clean fire-protection spray team to begin performing the on-sitewood coating spray job in accordance with the building constructionschedule.

As indicated at Block D in FIG. 52A, the fourth step of the methodinvolves, after the builder completes each completed section of woodframing with wood sheathing installed, but before any wallboard has beeninstalled, the spray technician (i) procures a supply of cleanfire-protection chemicals (CFIC) liquid solution, (ii) fills thereservoir tank of an airless liquid spraying system with the supply ofCFIC liquid, and (iii) then uses a spray gun to spray CFIC liquid in thereservoir tank, over all exposed interior wood surfaces of the completedsection of the wood-framed building under construction. FIGS. 49 and 50show an air-less liquid spraying system 101 for spraying CFIC liquidover all exposed interior surfaces of lumber and wood sheathing used ina completed section of the wood-framed building under construction, soas to form a Class-A fire-protective coating over such treated surfaces.

As indicated at Block A in FIG. 53, the first stage of this stepinvolves procuring water-based CFIC liquid for on-job-sitespray-treatment of raw untreated and treated lumber and sheathing usedinside a wood-framed building. In the preferred embodiment, HartindoAF31 from Hartindo Chemical, Ltd. (and available from its distributorNewstar Chemical of Malaysia) is used as the CFIC liquid employed by themethod of the present invention. Hartindo AF31 CFIC is anenvironmentally-friendly water-based, biodegradable and non-toxicsolution that is non-ozone depleting and does not require cleanupprocedures after usage. Hartindo AF31 CFIC is also effective for allclasses of fires: involving solid, carbonaceous materials; flammablefuels, thinners, etc.; gas, electricity fires, and energy fires; andmetal fire and oxidizing fires.

As indicated at Block B in FIG. 53, the second stage of this stepinvolves filling the tank of the air-less liquid spraying system 101with the procured supply of CFIC liquid.

As indicated at Block C in FIG. 53, the third stage of this stepinvolves using the spray nozzle gun 103 of the air-less liquid sprayingsystem 101 as shown in FIGS. 49 and 50, to a spray apply a uniformcoating of liquid clean fire inhibiting chemical (CFIC) liquid over allof the interior surfaces of the completed section of wood-framedbuilding being spray treated during the construction phase of thebuilding, in accordance with the principles of the present invention. Inthe illustrative embodiment, the liquid CIFC (i.e. Hartindo AF31) isapplied at a rate (i.e. coating coverage density) of about 590 squarefeet per gallon, although it is understood that this rate may vary fromillustrative embodiment, to illustrative embodiment.

The CFIC liquid used in the present invention clings to the wood onwhich it is sprayed, and its molecules combine with the (H+, OH—, O—)free radicals in the presence of fire, during combustion, to eliminatethis leg of the fire triangle so that fire cannot exist in the presenceof such a CFIC based coating.

FIGS. 51A and 51B shows a few illustrative examples of buildingconstruction job site locations where the spray-based fire protectivemethod of the present invention might be practiced with excellentresults. It is understood that such examples are merely illustrative,and no way limiting with regard to the present invention.

As indicated at Block E in FIG. 52B, during the fifth step of themethod, when the completed section of the building has been spray coatedwith clean fire inhibiting chemical (CFIC) liquid, the completedbuilding section is certified and marked as certified for visualinspection and insurance documentation purposes. Such marking caninvolving stamping a CFIC spray-coated sheath, or lumber board, with aseal or certificate using an indelible ink, with date, job ID #, sprayer#, and other information related to specific spray-coat fire-protectionjob that have been certified as a completed at that wood-framed buildingsection. Preferably, the architectural plans for the building, as wellas building schematics used on the job site, will have building sectionidentification numbers or codes, which will be used on the certificateof completion stamped onto the spray-coated fire-protected sheathing andlumber on the job site.

As part of the certification process, an on-job-site spray projectinformation sheet is maintained in an electronic database system,connected to a wireless portable data entry and record maintenancesystem. The on-job-site spray project information sheet would containnumerous basic information items, including, for example: Date; CustomerName; Weather Description and Temperature; Building Address; CustomerAddress: Customer Supervisor; Units of Part of the Building Sprayed;Sprayer Used; Spray Technician Supervisor; and Notes. Photographic andvideo recordings can also be made and stored in a database as part ofthe certification program, as will be described in greater detail below.

As indicated at Block F in FIG. 52B, during sixth step of the method, aseach section of the wood-framed building is constructed according to theconstruction schedule, the spray coating team continues to spray coatthe completed section, and certify and mark as certified each suchcompleted spray coated section of the building under construction.

As indicated at Block G in FIG. 52B, during the seventh step of themethod, when all sections of the building under construction have beencompletely spray coated with clean fire inhibiting chemical (CFIC)materials, suppressing fire ignition and suppression by capturing freeradicals (H+, OH—, O—) during the combustion phase, and certified assuch, the spray technicians remove the spray equipment from thebuilding, and the builder proceeds to the next stages of constructionand completes the building construction according to architectural andbuilding plans and specifications.

As indicated at Block H in FIG. 52B, during the eighth step of themethod, the spray technician then issues a certificate of completionwith respect to the application of clean fire-protection chemicals toall exposed wood surfaces on the interior of the wood-framed buildingduring its construction phase, thereby protecting the building from riskof total destruction by fire. Preferably, the certificate of completionshould bear the seal and signature of a professional engineer (PE) andthe building architect who have been overseeing and inspecting thebuilding construction project.

As indicated at Block I in FIG. 52B, during the ninth step of themethod, before applying gypsum board and/or other wall board coveringover the fire-protected spray-coated wood-framed building section 105,digital photographs and/or videos are captured and collected to visuallyshow certificates of completion stamped or otherwise posted onspray-coated fire-protected sheeting and/or lumber used in the woodframing of each completed building section. Such photographs and videoswill provide valuable visual evidence and job-site completiondocumentation, required or desired by insurance companies and/orgovernment building departments and/or safety agencies.

As indicated at Block J in FIG. 52B, during the tenth step of themethod, uploading captured digital photographs and videos collectedduring Block I, to a centralized web-based information server maintainedby the fire-protection spray coating technician company, or its agent,as a valued-added service provided for the benefit of the builder,property owner and insurance companies involved in the buildingconstruction project.

As indicated at Block K in FIG. 52B, during the eleventh step of themethod, all photographic and video records collected during Block I, anduploaded to the centralized web-based information server at Block J areautomatically archived indefinitely for best practice and legalcompliance purposes.

FIG. 54 shows a schematic table representation illustrating the flamespread and smoke development indices obtained through testing ofon-job-site Hartindo AF31 spray-treated lumber and sheathing producedusing the method of the illustrative embodiment described in FIGS. 49through 53, in accordance with ASTM E2768-1.

Advantages And Benefits Of The On-Job-Site Method Of Wood-Treatment AndFire-Protection By Way Of Spray Coating Of CFIC Liquid Over The SurfaceOf Exposed Interior And Exterior Wood Used in Wood-Framed Buildings

The on-site spray coating method of the present invention describedabove involves the use of CFIC liquid having the property of clingingonto the surface of the wood to which it is applied during on-job-sitespray-coating operations, and then inhibiting the ignition of a fire andits progression by interfering with the free-radicals (H+, OH—, O—)involved in the combustion phase of any fire. Hartindo AF31 liquid fireinhibitor meets these design requirements. In general, CFIC liquids thatmay be used to practice the on-site fire-protection method of thepresent invention suppresses fire by breaking free radical (H+, OH—, O—)chemical reactions occurring within the combustion phase of fire,quickly and effectively suppressing fire in a most effective manner,while satisfying strict design requirements during the constructionphase of a wood-framed building construction project. At the same time,the spray-based method of wood treatment and fire-protection will notdegrade the strength of the wood materials (i.e. Modulus of Elasticity(MOE) and the Modulus of Rupture (MOR)) when treated with the CFIC-basedliquid spray chemicals applied during the method of treatment.

The on-site wood lumber/sheathing spraying method of the presentinvention overcomes the many problems associated with pressure-treatedfire retardant treated (FRT) lumber, namely: “acid hydrolysis” alsoknown as “acid catalyzed dehydration” caused by FRT chemicals;significant losses in the Modulus of Elasticity (MOE), the Modulus ofRupture (MOR) and impact resistance of pressure-treated wood.

Modifications To The Present Invention Which Readily Come To Mind

The illustrative embodiments disclose the use of clean fire inhibitingchemicals (CFIC) from Hartindo Chemicatama Industri, particular HartindoAF21 and AF31 and DecTan chemical, for applying and formingCFIC-coatings to the surface of wood, lumber, and timber, and otherengineering wood products. However, it is understood that alternativeCFIC liquids will be known and available to those with ordinary skill inthe art to practice the various methods of Class-A fire-protectionaccording to the principles of the present invention.

While several modifications to the illustrative embodiments have beendescribed above, it is understood that various other modifications tothe illustrative embodiment of the present invention will readily occurto persons with ordinary skill in the art. All such modifications andvariations are deemed to be within the scope and spirit of the presentinvention as defined by the accompanying Claims to Invention.

1. A system for producing wood-framed buildings having Class-Afire-protection against total fire destruction during constructionphase, and for marking and certifying the same, said system comprising:a reservoir for containing a supply of clean fire inhibiting liquidchemical (CFIC) liquid for spray application over over the interiorsurfaces of raw and treated lumber and sheathing used in a completedsection of a wood-framed assemblies in a wood-framed building during itsconstruction phase; a liquid spray pumping subsystem operably connectedto said reservoir tank containing said supply of CFIC liquid; ahand-held liquid spray gun, operably connected to said liquid spraypumping subsystem, for spraying CFIC liquid from said reservoir tankonto the exposed interior wood surfaces of lumber and sheathing used toconstruct each completed section of said wood-framed building, so as toform a CFIC coating on the treated interior wood surfaces providingClass-A fire-protection to said completed section of said wood-framedbuilding; and apparatus for visually marking and certifying that exposedinterior wood surfaces of each completed section of said wood-framedbuilding construction have been properly spray-coated to provide Class-Afire-protection within said completed section of said wood-framedbuilding.
 2. A system for producing wood-framed buildings having Class-Afire-protection against total fire destruction during the constructionphase, said system comprising: a reservoir for containing a supply ofclean fire inhibiting liquid chemical (CFIC) liquid for sprayapplication over over the interior surfaces of raw and treated lumberand sheathing used in a completed section of a wood-framed assemblies ina wood-framed building during its construction phase; a liquid spraypumping subsystem operably connected to the reservoir tank containingthe supply of CFIC liquid; a hand-held liquid spray gun, operablyconnected to the liquid spray pumping subsystem, for spraying CFICliquid from the reservoir tank onto the exposed interior wood surfacesof lumber and sheathing used to construct each completed section of thewood-framed building, to form a CFIC coating on the treated interiorwood surfaces providing Class-A fire-protection to the completed sectionof the wood-framed building; wherein said CFIC-coated wood surfacessuppress fire ignition and suppression by interfering with free radicals(H+, OH—, O—) produced during the combustion phase of a fire; andapparatus for visually marking and certifying that exposed interior woodsurfaces of each completed section of said wood-framed buildingconstruction have been properly spray-coated to provide Class-Afire-protection within said completed section of said wood-framedbuilding.
 3. A method of producing wood-framed buildings having Class-Afire-protection against total fire destruction during the constructionphase, comprising the steps: (a) providing a reservoir for containing asupply of clean fire inhibiting liquid chemical (CFIC) liquid for sprayapplication over over the interior surfaces of raw and treated lumberand sheathing used in a completed section of a wood-framed assemblies ina wood-framed building during its construction phase; (b) providing aliquid spray pumping subsystem operably connected to the reservoir tankcontaining the supply of CFIC liquid; (c) using a hand-held liquid spraygun, operably connected to the liquid spray pumping subsystem, forspraying CFIC liquid from the reservoir tank onto the exposed interiorwood surfaces of lumber and sheathing used to construct each completedsection of the wood-framed building, so as to form a CFIC coating on thetreated interior wood surfaces providing Class-A fire-protection to thecompleted section of the wood-framed building; and (d) visually markingand certifying that exposed interior wood surfaces of each completedsection of said wood-framed building construction have been properlyspray-coated to provide Class-A fire-protection within said completedsection of said wood-framed building.